FOREWORD
This repair manual has been prepared to provide essential information on body panel repair methods (including cutting and
welding operations, but excluding painting) for the TOYOTA
YARIS.
Applicable models: KSP90 series
Applicable models: NCP90, 91 series
This manual consists of body repair methods, exploded diagrams and illustrations of the body components and other information relating to body panel replacement such as handling
precautions, etc. However, it should be noted that the front fenders of, this TOYOTA model are bolted on and require no welding.
When repairing, don’t cut and join areas that are not shown in
this manual. Only work on the specified contents to maintain
body strength.
Body construction will sometimes differ depending on specifications and country of destination. Therefore, please keep in mind
that the information contained herein is based on vehicles for
general destinations.
For the repair procedures and specifications other than collisiondamaged body components of the TOYOTA YARIS refer to the
repair manuals.
If you require the above manuals, please contact your TOYOTA
dealer.
All information contained in this manual is the most up-to-date at
the time of publication. However, specifications and procedures
are subject to change without prior notice.
VIEWS OF THIS TEXT
Scope of the repair work explanation
This text explains the welding panel replacement instructions from the vehicle’s white body condition. We have abbreviated the explanations of the removal and reinstallation of the equipment parts
up to the white body condition and of the installation, inspection, adjustment and final inspection of
equipment parts after replacing the weld panel.
Section categories
This manual has been divided as shown below.
Section Title
Contents
Examples
INTRODUCTION
Explanation of general body repair.
Views of weld panel replacement instructions.
Cautionary items.
Views of weld panel replacement instructions.
BODY PANEL REPLACEMENT
Instructions for replacing the weld panels
from the white body condition, from which
bolted parts have been removed, with
individual supply parts.
Front side member replacement.
Quarter panel replacement.
BODY DIMENSIONS
Body aligning measurements.
Dimension diagrams.
PAINT COATING
Scope and type of anti-rust treatment, etc.
together with weld panel replacement.
Under coating.
Body sealer.
Contents omitted in this manual.
Make sure to perform the following essential procedures, although they are omitted in this manual.
(1) Jack and lift operations.
(2) Clean and wash removed parts, if necessary.
(3) Visual inspection.
INTRODUCTION
IN-1
GENERAL REPAIR INSTRUCTIONS
1.
WORK PRECAUTIONS
(a) VEHICLE PROTECTION
(1) When welding, protect the painted surfaces, windows,
seats and carpet with heat resistant, fireproof covers.
Glass Cover
Seat Cover
F10001A
(b) SAFETY
(1) Never stand in a direct line with the chain when using a
puller on the body or frame, and be sure to attach a
safety cable.
WRONG
F10002A
(2) Before performing repair work, check for fuel leaks.
If a leak is found, be sure to close the opening completely.
(3) If it is necessary to use a flame in the area of the fuel
tank, first remove the tank and plug the fuel line.
WRONG
F10003A
(c)
F10004A
SAFETY WORK CLOTHES
(1) In addition to the usual mechanic’s wear, cap and
safety shoes, the appropriate gloves, head protector,
glasses, ear plugs, face protector, dust-prevention
mask, etc. should be worn as the situation demands.
Code
Name
A
Dust-Prevention Mask
B
Face Protector
C
Eye Protector
D
Safety Shoes
E
Welder’s Glasses
F
Ear Plugs
G
Head Protector
H
Welder’s Gloves
INTRODUCTION
IN-2
2.
HANDLING PRECAUTIONS OF PLASTIC BODY PARTS
(1) The repair procedure for plastic body parts must conform with the type of plastic material.
(2) Plastic body parts are identified by the codes in the following table.
(3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, painting etc.), consideration must be given to the properties of the plastic.
Code
Material
name
Heat*
resistant
temperature
limit C (F)
Resistance to
alcohol or gasoline
Notes
AAS
Acrylonitrile
Acrylic Styrene
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
ABS
Acrylonitrile
Butadiene Styrene
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
AES
Acrylonitrile
Ethylene Styrene
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
ASA
Acrylonitrile
Styrene
Acrylate
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
CAB
Cellulose
Acetate
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
EPDM
Ethylene
Propylene
100
(212)
Alcohol is harmless.
Gasoline is harmless if applied only for
short time in small amounts.
Most solvents are harmless
but avoid dipping in gasoline,
solvents, etc.
FRP
Fiber
Reinforced
Plastics
180
(356)
Alcohol and gasoline are harmless.
Avoid alkali.
EVA
Ethylene
Acetate
70
(158)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
E / VAC
Ethylene /
Vinyl
Acetate
Copolymer
Resin
70
(158)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
PA
Polyamide
(Nylon)
80
(176)
Alcohol and gasoline are harmless.
Avoid battery acid.
PBT
Polybutylene
Terephthalate
160
(320)
Alcohol and gasoline are harmless.
Most solvents are harmless.
PC
Polycarbonate
120
(248)
Alcohol is harmless.
Avoid gasoline, brake fluid,
wax, wax removers and
organic solvents. Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.
INTRODUCTION
Code
Material
name
Heat*
resistant
temperature
limit C (F)
Resistance to
alcohol or gasoline
IN-3
Notes
PE
Polyethylene
80
(176)
Alcohol and gasoline are harmless.
Most solvents are harmless.
PET
Polyethylene
Terephthalate
75
(167)
Alcohol and gasoline are harmless.
Avoid dipping in water.
PMMA
Polymethyl
Methacrylate
80
(176)
Alcohol is harmless if applied only for
short time in small amounts.
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
Polyoxymethylene
(Polyacetal)
100
(212)
Alcohol and gasoline are harmless.
Most solvents are harmless.
PP
Polypropylene
80
(176)
Alcohol and gasoline are harmless.
Most solvents are harmless.
PPF
Composite
Reinforced
Polypropylene
80
(176)
Alcohol and gasoline are harmless.
Most solvents are harmless.
PPO
Modified
Polyphenylene
Oxide
100
(212)
Alcohol is harmless.
Gasoline is harmless if
applied only for quick wiping
to remove grease.
Polystyrene
60
(140)
Alcohol and gasoline are harmless if
applied only for short time in small
amounts.
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
PUR
Polyurethane
80
(176)
Alcohol is harmless if applied only for very
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
PVC
Polyvinylchloride
(Vinyl)
80
(176)
Alcohol and gasoline are harmless if
applied only for short time in small
amounts (e.g., quick wiping to remove
grease).
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
SAN
Styrene
Acrylonitrile
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
TPO
Thermoplastic
Olefine
80
(176)
Alcohol is harmless.
Gasoline is harmless if applied only for
short time in small amounts.
Most solvents are harmless
but avoid dipping in gasoline,
solvents, etc.
TPU
Thermoplastic
Polyurethane
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
TOYOTA
Super
Olefine Polymer
80
(176)
Alcohol and gasoline are harmless.
Most solvents are harmless.
Unsaturated
Polyester
110
(233)
Alcohol and gasoline are harmless.
Avoid alkali.
POM
PS
TSOP
UP
*Temperatures higher than those listed here may result in material deformation during repair.
INTRODUCTION
IN-4
3.
LOCATION OF PLASTIC BODY PARTS
Parts Name
Code
Front Bumper Cover
TSOP
Radiator Grille
TSOP
Headlight
PC/PP
Fog Light
TSOP
Front Pillar Upper Cover
AES
Side Turn Signal Light
PMMA/PC/ABS
Cowl Top Ventilator Louver
TSOP/PP/PE
Rear Body Mudguard
PP
Door Outside Handle
PA/PC/PBT
Outer Rear View Mirror
PP/PA/ABS ASA
Front Door Window Frame Front Moulding
ASA
Front Spoiler Cover
TSOP
Front Fender Mudguard
PP
Back Door Outside Handle
PA
License Plate Light
PC
Rear Combination Light
PMMA/ASA
Rear Bumper Cover
TSOP
HINT:
Resin material differs depending on model.
/ Made up of 2 or more kinds of materials.
INTRODUCTION
IN-5
HOW TO USE THIS MANUAL
1.
BODY PANEL REPLACEMENT IN THIS MANUAL
BODY PANEL REPLACEMENT
QUARTER PANEL (CUT)
REPLACEMENT
REMOVAL
POINT
1. Remove the [A] at the same time.
PART NAME
[A] Fuel filler opening lid
200 mm (7.87 in.)
REPLACEMENT PART AND METHOD
QUARTER PANEL (CUT)
Replacement method
(ASSY)...Assembly replacement
(CUT)...Major cutting (less than 1/2 of part used)
(CUT-H)...Half cutting (about 1/2 of part used)
(CUT-P)...Partial cutting (most of part used)
Replacement part
REMOVAL CONDITIONS
PART LOCATION
REMOVAL DIAGRAM
Describes in detail the removal of the damaged part involving repair by cutting.
REMOVAL GUIDE
Provides additional information to more efficiently help you perform the removal.
F13890A
INTRODUCTION
IN-6
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
POINT
1. Before temporarily installing the new parts, apply sealer to the wheel arch.
HINT
1) Apply body sealer about 5 mm (0.20 in.) front the flange, avoiding any oozing.
2) Apply sealer evenly, about 3−4 mm (0.12−0.16 in.) in diameter
3) For other sealing points, refer to section PC.
INSTALLATION CONDITIONS
INSTALLATION DIAGRAM
Describes in detail the installation of the new parts involving repair by welding and/or
cutting, but excluding painting.
INSTALLATION GUIDE
Provides additional information to more efficiently help you perform the installation.
SYMBOLS
(See page IN-7)
INSTALLATION OF WELD POINTS
Weld method and panel position symbols (See page IN-9)
PART NAME
F13891A
INTRODUCTION
2.
IN-7
SYMBOLS
The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas
and the types of weld required.
SYMBOLS
MEANING
ILLUSTRATION
CUT AND JOIN LOCATION
(Saw Cut)
CUT AND JOIN LOCATION
(Cut Location for
Supply Parts)
CUT LOCATION
CUT WITH DISC
SANDER, ETC.
BRAZE
(Removal)
BRAZE
(Installation)
WELD POINTS
SPOT WELD OR
MIG PLUG WELD
(See page IN-9)
CONTINUOUS
MIG WELD
(BUTT WELD)
CONTINUOUS
MIG WELD
(TACK WELD)
BODY SEALER
F13893A
INTRODUCTION
IN-8
SYMBOLS
—
MEANING
ILLUSTRATION
Assembly Mark
—
—
BODY SEALER
(Flat Finishing)
—
BODY SEALER
(No Flat Finishing)
F13894A
INTRODUCTION
IN-9
3. ILLUSTRATION OF WELD POINT SYMBOLS
EXAMPLE:
REMOVAL
INSTALLATION
Weld points
Weld points
Remove weld point and panel position
SYMBOLS
MEANING
ILLUSTRATION
Remove
Weld
Points
Weld method and panel position
SYMBOLS
MEANING
ILLUSTRATION
Spot Weld
(Outside)
MIG Plug
Weld
(Middle)
(Inside)
HINT: Panel position symbols are as seen from
the working posture.
Spot MIG
Weld
F13892A
INTRODUCTION
IN-10
PROPER AND EFFICIENT WORK
PROCEDURES
1.
REMOVAL
(a) PRE-REMOVAL MEASURING
(1) Before removal or cutting operations, take measurements in accordance with the dimensions diagram. Always use a puller to straighten a damaged body or
frame.
F10007A
(b) CUTTING AREA
(1) Always cut in a straight line and avoid reinforced
areas.
Cutting Okay
Reinforcement
Corners
F10008A
(c)
WRONG
PRECAUTIONS FOR DRILLING OR CUTTING
(1) Check behind any area to be drilled or cut to ensure
that there are no hoses, wires, etc., that may be damaged.
HINT: See “Handling Precautions on Related Components” on page IN-15.
F10009A
(d) REMOVAL OF ADJACENT COMPONENTS
(1) When removing adjacent components, apply protective tape to the surrounding body and your tools to prevent damage.
HINT: See “Handling Precautions on Related Components” on page IN-15.
F10010A
INTRODUCTION
2.
IN-11
PREPARATION FOR INSTALLATION
(a) SPOT WELD POINTS
(1) When welding panels with a combined thickness of
over 3 mm (0.12 in.), use a MIG (Metal Inert Gas)
welder for plug welding.
HINT: Spot welding does not provide sufficient durability for panels with a combined thickness of over 3
mm (0.12 in.).
Less than
3 mm
F10011A
(b) APPLICATION OF WELD-THROUGH PRIMER
(SPOT SEALER)
(1) Remove the paint from the portion of the new parts
and body to be welded, and apply weld-through primer.
F10012A
(c)
MAKING HOLES FOR PLUG WELDING
(1) For areas where a spot welder cannot be used, use a
puncher or drill to make holes for plug welding.
REFERENCE:
mm (in.)
Thickness of welded portion
Puncher
Size of plug hole
1.0 (0.04) under
5 (0.20) ø over
1.0 (0.04) − 1.6 (0.06)
6.5 (0.26) ø over
1.7 (0.07) − 2.3 (0.09)
8 (0.31) ø over
2.4 (0.09) over
10 (0.39) ø over
F10013A
(d) SAFETY PRECAUTIONS FOR ELECTRICAL COMPONENTS
(1) When welding, there is a danger that electrical components will be damaged by the electrical current flowing
through the body.
(2) Before starting work, disconnect the negative terminal
of the battery and ground the welder near the welding
location of the body.
F10014A
20 − 30 mm
Air Saw
Overlap
F10015A
(e) ROUGH CUTTING OF JOINTS
(1) For joint areas, rough cut the new parts, leaving 20 −
30 mm (0.79 − 1.18 in.) of overlap.
INTRODUCTION
IN-12
3.
Body Measurement Diagrams
INSTALLATION
(a) PRE-WELDING MEASUREMENTS
(1) Always take measurements before installing underbody or engine components to ensure correct assembly. After installation, confirm proper fit.
F10016A
(b) WELDING PRECAUTIONS
(1) The number of welding spots should be as follows.
Spot weld: 1.3 X No. of manufacturer’s spots.
Plug weld: More than No. of manufacturer’s plugs.
(2) Plug welding should be done with a MIG (Metal Inert
Gas) welder. Do not gas weld or braze panels at areas
other than specified.
WRONG
F10017A
(c)
CORRECT
POST-WELDING REFINISHING
(1) Always check the welded spots to ensure they are secure.
(2) When smoothing out the weld spots with a disc grinder, be careful not to grind off too much as this will weaken the weld.
WRONG
F10018A
Old
Spot
Locations
New Spot
Locations
(d) SPOT WELD LOCATIONS
(1) Avoid welding over previously welded areas.
F10020A
Tip Cutter
F10019A
(e) SPOT WELDING PRECAUTIONS
(1) The shape of the tip point of the spot welder significantly affects the strength of the weld. Therefore,
maintain the tip point in the proper shape, and allow it
to cool after every five or six spots.
(2) Completely remove the paint from the areas to be spot
welded, including the seams and the surfaces that
come in contact with the welding tip.
(3) Use a sander to remove any burrs that are created
during spot welding.
INTRODUCTION
4.
Sealer Gun
IN-13
ANTI-RUST TREATMENT AFTER INSTALLATION
(BEFORE PAINTING PROCESS)
(a) BODY SEALER APPLICATION
(1) For water-proofing and anti-corrosion measures, always apply the body sealer to the body panel seams
and hems of the doors, hood, etc.
F10021A
(b) UNDERCOAT APPLICATION
(1) To prevent corrosion and protect the body from damage by flying stones, always apply sufficient undercoating to the bottom surface of the under body and
inside of the wheel housings.
F10022A
5.
ANTI-RUST TREATMENT AFTER INSTALLATION
(AFTER PAINTING PROCESS)
(a) ANTI-RUST AGENT (WAX) APPLICATION
(1) To preserve impossible to paint areas from corrosion,
always apply sufficient anti-rust agent (wax) to the inside of the hemming areas of the doors and hood, and
around the hinges, or the welded surfaces inside the
box-shaped cross sections of the side members, body
pillar, etc.
F10023A
INTRODUCTION
IN-14
6.
ANTI-RUST TREATMENT BY PAINTING
REFERENCE:
Painting prevents corrosion and protects the sheet
metal from damage. In this section, anti-chipping paint
only for anti-corrosion purpose is described.
(a) ANTI-CHIPPING PAINT
(1) To prevent corrosion and protect the body from damage by flying stones, etc., apply anti-chipping paint to
the rocker panel, wheel arch areas, balance panel,
etc.
HINT:
Depending on the model or the application area, there
are cases where the application of anti-chipping paint
is necessary before the second coat or after the top
coat.
Apply the anti-chipping paint after
the top coat.
Apply the anti-chipping paint before
the second coat.
Anti-Chipping Paint
Top Coat
Second Coat
Top Coat
Second Coat
Anti-Chipping Paint
Under Coat (ED Primer)
Under Coat (ED Primer)
Steel Metal
Steel Metal
F10024A
INTRODUCTION
IN-15
HANDLING PRECAUTIONS ON RELATED COMPONENTS
1.
BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and
notes given in the brake (32) section of the repair manual for the relevant model when handling brake
system parts.
NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC system.
2.
DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance and
vibration resistance of the vehicle. After installing components in the sections listed in the table below,
perform alignments to ensure correct mounting angles and dimensions. Body repair must be particularly
accurate to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions given in the repair manual for the relevant model during alignment and section DI of this section.
3.
Component to be aligned
Section of repair manual
for relevant model
Front Wheels
Front Suspension (26) section
Rear Wheels
Rear Suspension (27) section
COMPONENTS ADJACENT TO THE BODY PANELS
Various types of component parts are mounted directly on or adjacently to the body panels. Strictly observe the following precautions to prevent damaging these components and the body panels during handling.
Before repairing the body panels, remove their components or apply protective covers over the components.
Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components and the body paint.
Before removing components from the outer surface of the body, attach protective tape to the body to
ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.
Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.
4.
ECU (ELECTRONIC CONTROL UNIT)
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.
Before starting electric welding operations, disconnect the negative (−) terminal cable from the battery.
When the negative (−) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be canceled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seats and outside rear view mirrors, which are
all equipped with a memory function, it is not possible to make a record of the memory contents.
So when the operation is finished, it will be necessary to explain this fact to the customer, and request
the customer to adjust the features and reset the memory.
Do not expose the ECUs to ambient temperatures above 80C (176F).
NOTICE: If it is possible the ambient temperature may reach 80C (176F) or more, remove the ECUs
from the vehicle before starting work.
Be careful not to drop the ECUs and not to apply physical shocks to them.
IN-16
INTRODUCTION
PRECAUTIONS FOR REPAIRING BODY
STRUCTURE PANELS
1.
HEAT REPAIR FOR BODY STRUCTURE
PANELS
Toyota prohibits the use of the heat repair method on body
structure panels when repairing a vehicle damaged in a collision.
Panels that have high strength and rigidity, as well as a long
life span for the automobile body are in high demand.
At Toyota, in order to fulfill these requirement, we use high
tensile strength steel sheets and rust preventive steel
sheets on the body. High tensile steel sheets are made with
alloy additives and a special heat treatment in order to improve the strength.
To prevent the occurrence of rust for a long period of time,
the surface of the steel is coated with a zinc alloy.
If body structure parts are heat repaired with an acetylene
torch or other heating source, the crystalline organization of
the steel sheet will change and the strength of the steel
sheet will be reduced. The ability of the body to resist rust is
significantly lowered as well since the rust resistant zinc
coating is destroyed by heat and the steel sheet surface is
oxidized.
2.
STRUCTURE PANEL KINKS
A sharp deformation angle on a panel that cannot be returned to its original shape by pulling or hammering is
called a kink.
Structural parts are designed to perform in their original
shape. If parts are deformed in an accident, or if the deformed parts are repaired and reused, the parts may be unable to perform as intended.
It is necessary to replace the part where the kink has occurred.
INTRODUCTION
3.
IN-17
IMPACT BEAM REPAIR
The impact beam and bracket are necessary and important
parts that help reduce the probability of injury to passengers in side collisions.
For impact beams, we use special high tensile strength
steel.
The high tensile strength steel maintains its special crystalline organization by heat treatment or alloy additives.
Structural parts are designed to perform in their original
shape. If parts are deformed in an accident, or if the deformed parts are repaired and reused, the parts may be unable to perform as intended.
If the impact beam or bracket is damaged, replace the door
assembly with the damaged beam.
Also, the bumper reinforcement is a necessary and important part that helps reduce the probability of injury to passengers in front collisions, and for the same reasons explained above, should be replaced if damaged.
IN-18
INTRODUCTION
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual.
ABS
Antilock Brake System
A/C
Air Conditioner
assy
assembly
ECT
Electronic Controlled Transmission
ECU
Electronic Control Unit
e.g.
Exempli Gratia (for Example)
Ex.
Except
FWD
Front Wheel Drive Vehicles
2WD
Two Wheel Drive Vehicles
4WD
Four Wheel Drive Vehicles
in.
inch
LH
Left-hand
LHD
Left-hand Drive
MIG
Metal Inert Gas
M/Y
Model Year
PPS
Progressive Power Steering
RH
Right-hand
RHD
Right-hand Drive
SRS
Supplemental Restraint System
SSM
Special Service Materials
w/
with
w/o
without
BODY PANEL REPLACEMENT
BP-1
RADIATOR SUPPORT (ASSY)
REPLACEMENT
F22816A
REMOVAL
F22816
POINT
1
*1: Bolt
BP-2
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F22817
POINT
1
Inspect the fitting of the headlight, front fender, hood and other related parts, before welding as this affects the
appearance of the finish.
2
*1: Bolt
BODY PANEL REPLACEMENT
BP-3
1,324 mm
530 mm
944 mm
742 mm
F22818
POINT
1
Measure the dimensions before installing the headlight.
2
These values are reference values.
530 mm (20.87 in.)
742 mm (29.21 in.)
944 mm (37.17 in.)
1,324 mm (52.13 in.)
BP-4
BODY PANEL REPLACEMENT
FRONT FENDER MOUNTING BRACKET
(ASSY)
REPLACEMENT
F22819A
REMOVAL
F22819
BODY PANEL REPLACEMENT
BP-5
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F22820
POINT
1
Inspect the fitting of the front fender and other related parts before welding as this affects the appearance of the
finish.
BP-110
BODY PANEL REPLACEMENT
QUARTER PANEL UPPER EXTENSION
(CUT): Hatchback
REPLACEMENT
With the back door opening trough removed.
F22867A
REMOVAL
130 mm
F22867
130 mm (5.12 in.)
BODY PANEL REPLACEMENT
BP-111
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F22868
BP-112
BODY PANEL REPLACEMENT
FLOOR SIDE RAIL FRONT PANEL (ASSY):
Hatchback
REPLACEMENT
With the body lower back panel removed.
F22869A
REMOVAL
F23327
BODY PANEL REPLACEMENT
BP-113
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
(10 mm 2)
F23328
10 mm ( 0.39 in.)
BP-114
BODY PANEL REPLACEMENT
FLOOR SIDE RAIL FRONT PANEL (ASSY):
Sedan
REPLACEMENT
With the body lower back panel removed.
F24846A
REMOVAL
F24846-1
POINT
1
Remove [A] at the same time.
PART NAME
[A] Rear Floor Pan Extension
BODY PANEL REPLACEMENT
BP-115
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
(10 mm x 2)
F24846-2
10 mm (0.39 in.)
BODY PANEL REPLACEMENT
BP-123
REAR FLOOR SIDE PANEL EXTENSION
(ASSY): Hatchback
REPLACEMENT
With the quarter panel and body lower back panel removed.
F22875A
REMOVAL
F22875
POINT
1
After removing the rear floor side panel extension, remove [A].
PART NAME
[A] Quarter Wheel Housing Extension
BP-124
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F22876
POINT
1
After installing [A], install the new parts.
PART NAME
[A] Quarter Wheel Housing Extension
BODY PANEL REPLACEMENT
BP-116
REAR FLOOR PAN (ASSY): Hatchback
REPLACEMENT
With the body lower back panel and floor side rail front panel removed.
F22871A
REMOVAL
[EX. U.S.A., CANADA]
F23347
BODY PANEL REPLACEMENT
BP-117
[U.S.A., CANADA]
F23345
POINT
1
After removing [A], remove the rear floor pan.
PART NAME
[A] Rear Floor Brace Braket
BP-118
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
[EX. U.S.A., CANADA]
F23348
PART NAME
[B] Spare Wheel Clamp Bracket
[C]
Actuator Cover No.3 Bracket
BODY PANEL REPLACEMENT
BP-119
[U.S.A., CANADA]
F23346
POINT
1
After installing the new parts, install [A].
PART NAME
[A] Rear Floor Brace Bracket
[D] Fuel Tube No.2 Bracket
[B] Spare Wheel Clamp Bracket
[E] Fuel Tube Bracket
BODY PANEL REPLACEMENT
BP-125
REAR FLOOR PAN EXTENSION (ASSY):
Sedan
REPLACEMENT
With the body lower back panel removed.
F24852A
REMOVAL
50 mm
F24852-1
POINT
1
Remove [A] at the same time.
PART NAME
[A] Floor Side Rail Front Panel
50 mm (1.97 in.)
BP-126
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F24852-2
PART NAME
[A] Floor Side Rail Front Panel
BP-120
BODY PANEL REPLACEMENT
REAR FLOOR PAN (ASSY): Sedan
REPLACEMENT
With the floor side rail front panel removed.
F24848A
REMOVAL
F24848
BODY PANEL REPLACEMENT
BP-121
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
[EX. U.S.A., CANADA]
[U.S.A., CANADA]
F24849-1
PART NAME
[A] Actuator Cover No.3 Bracket
[C] Weld Bolt
[E] Fuel Tube No.2 Bracket
[B]
[D]
Spare Wheel Clamp Bracket
Fuel Tube Bracket
BP-122
BODY PANEL REPLACEMENT
F24849-2
BODY PANEL REPLACEMENT
BP-127
REAR FLOOR CROSSMEMBER NO.2
(ASSY): Hatchback
REPLACEMENT
F22877A
REMOVAL
F22877
BP-128
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F22878
BODY PANEL REPLACEMENT
BP-129
REAR FLOOR CROSSMEMBER NO.2
(ASSY): Sedan
REPLACEMENT
F24853A
REMOVAL
F24853-1
BP-130
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F24853-2
BODY PANEL REPLACEMENT
BP-135
ROOF PANEL (ASSY): Hatchback
REPLACEMENT
F22885A
REMOVAL
3 Door :
5 Door :
3 Door :
5 Door :
F23331
BP-136
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
3 Door :
5 Door :
3 Door :
5 Door :
F23332
POINT
1
Before temporarily installing the new parts, apply body sealer to the window shield header panel, roof panel
reinforcement and back window upper frame.
HINT:
1) Apply just enough sealer for the new parts to make contact.
BODY PANEL REPLACEMENT
BP-6
FRONT FENDER APRON (ASSY)
REPLACEMENT
With the cowl top side panel removed.
F22821A
REMOVAL
[RH]
[LH]
F22821
BODY PANEL REPLACEMENT
BP-7
F22822
BODY PANEL REPLACEMENT
BP-8
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
[RH]
[LH]
F22823
POINT
1
Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front
wheel alignment.
2
Inspect the fitting of the front fender, hood and other related parts before welding as this affects the appearance
of the finish.
BODY PANEL REPLACEMENT
BP-9
F22824
BODY PANEL REPLACEMENT
BP-137
ROOF PANEL (ASSY): Sedan
REPLACEMENT
F24859A
REMOVAL
F24859-1
BP-138
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F248860-1
POINT
1
Before temporarily installing the new parts, apply body sealer to the window shield header panel, roof panel
reinforcement and back window upper frame.
HINT:
1) Apply just enough sealer for the new parts to make contact.
BODY PANEL REPLACEMENT
BP-131
REAR FLOOR SIDEMEMBER (CUT):
Hatchback
REPLACEMENT
With the body lower back panel removed.
F22881A
REMOVAL
110 mm
40 mm
F23329
POINT
1
After removing [A], remove the rear floor sidemember.
PART NAME
[A] Floor Side Rail Front Panel
40 mm (1.57 in.)
110 mm (4.33 in.)
BP-132
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F23330
PART NAME
[A] Floor Side Rail Front Panel
BODY PANEL REPLACEMENT
BP-139
OUTER PANEL INSTALLATION TORQUE
[Hatchback]
T = 13.0 N.m
T = 11.5 N.m
T = 5.5 N.m
T = 5.5 N.m
T = 5.5 N.m
T = 5.0 N.m
T = 5.5 N.m
T = 40.0 N.m
T = 40.0 N.m
T = 5.0 N.m
T = 5.5 N.m
T = 5.0 N.m
F22801
5.0
N.m
(51
kgf.cm,
44
in..lbf)
13.0 N.m (133 kgf.cm, 10 ft..lbf)
5.5
N.m
(56
kgf.cm,
49
in..lbf)
40.0 N.m (408 kgf.cm, 30 ft..lbf)
11.5
N.m
(117
kgf.cm,
—
8
ft..lbf)
BODY PANEL REPLACEMENT
BP-140
[Sedan]
T = 13.0 N.m
T = 5.5 N.m
T = 11.5 N.m
T = 5.5 N.m
T = 5.5 N.m
T = 5.5 N.m
T = 5.0 N.m
T = 40.0 N.m
T = 40.0 N.m
T = 5.0 N.m
T = 5.0 N.m
T = 5.5 N.m
T = 5.0 N.m
F24861-1
5.0
N.m
(51
kgf.cm,
44
in..lbf)
13.0 N.m (133 kgf.cm, 10 ft..lbf)
5.5
N.m
(56
kgf.cm,
49
in..lbf)
40.0 N.m (408 kgf.cm, 30 ft..lbf)
11.5
N.m
(117
kgf.cm,
—
8
ft..lbf)
BODY PANEL REPLACEMENT
BP-141
[Hatchback 3 Door]
T = 26.0 N.m
T = 26.0 N.m
F23333
26.0
N.m
(265
kgf.cm,
19
ft..lbf)
—
—
BODY PANEL REPLACEMENT
BP-142
[Hatchback 5 Door]
T = 26.0 N.m
T = 26.0 N.m
T = 26.0 N.m
T = 26.0 N.m
F23334
26.0
N.m
(265
kgf.cm,
19
ft..lbf)
—
—
BODY PANEL REPLACEMENT
BP-143
[Sedan]
T = 26.0 N.m
T = 26.0 N.m
T = 26.0 N.m
T = 26.0 N.m
F24862-1
26.0
N.m
(265
kgf.cm,
19
ft..lbf)
—
—
BODY PANEL REPLACEMENT
BP-144
[Hatchback]
T = 11.5 N.m
T = 27.0 N.m
T = 19.0 N.m
F22803
11.5
N.m
(117
kgf.cm,
8
ft..lbf)
19.0
N.m
(194
kgf.cm,
14
ft..lbf)
27.0
N.m
(275
kgf.cm,
20
ft..lbf)
BODY PANEL REPLACEMENT
BP-145
[Sedan]
T = 7.0 N.m
T = 19.0 N.m
F24863-1
7.0
N.m
(71
kgf.cm,
62
in..lbf)
19.0
N.m
(194
kgf.cm,
14
ft..lbf)
—
BODY PANEL REPLACEMENT
BP-133
REAR FLOOR SIDEMEMBER (ASSY): Sedan
REPLACEMENT
With the rear floor pan removed.
F24855A
REMOVAL
F24855-1
BP-134
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F24855-2
BODY PANEL REPLACEMENT
BP-146
FIT STANDARDS
[Hatchback]
7.5 mm
2.0 mm
3.5 mm
3.7 mm
3.7 mm
6.0 mm
5.4 mm
2.8 mm
6.0 mm
F23343
2.0 mm (0.079 in.)
2.8 mm (0.110 in.)
3.5 mm (0.138 in.)
3.7 mm (0.146 in.)
5.4 mm (0.213 in.)
6.0 mm (0.236 in.)
7.5 mm (0.295 in.)
—
—
BODY PANEL REPLACEMENT
BP-147
[Sedan]
11.85 mm
2.7 mm
4.35 mm
3.5 mm
4.65 mm
4.1 mm
2.7 mm
4.0 mm
6.45 mm
F24864-1
2.7 mm (0.106 in.)
3.5 mm (0.138 in.)
4.0 mm (0.157 in.)
4.1 mm (0.161 in.)
4.35 mm (0.171 in.)
4.65 mm (0.183 in.)
6.45 mm (0.254 in.)
11.85 mm (0.467 in.)
—
BODY PANEL REPLACEMENT
BP-148
[Hatchback 3 Door]
5.0 mm
4.0 mm
4.0 mm
5.6 mm
[Hatchback 5 Door]
5.0 mm
5.0 mm
4.0 mm
4.8 mm
4.0 mm
5.6 mm
5.6 mm
F23335
4.0 mm (0.157 in.)
4.8 mm (0.189 in.)
5.0 mm (0.197 in.)
5.6 mm (0.220 in.)
—
—
BODY PANEL REPLACEMENT
BP-149
[Sedan]
4.7 mm
4.7 mm
4.8 mm
4.0 mm
4.0 mm
5.7 mm
5.7 mm
F24865-1
4.0 mm (0.157 in.)
4.7 mm (0.185 in.)
4.8 mm (0.189 in.)
5.7 mm (0.224 in.)
—
—
PAINT COATING
PC-1
BODY PANEL SEALING AREAS
HINT:
1) Prior to applying body sealer, clean the area with a rag soaked in silicone remover.
2) If weld-through primer was used, first wipe off any excess and than coat with anti-corrosion primer before applying body sealer.
3) Wipe off excess body sealer with a rag soaked in silicone remover.
4) Besure to repair as necessary if the body sealer shows signs of damage such as peeling or cracking.
Flat Finishing
1.
No Flat Finishing
ENGINE COMPARTMENT
[Hatchback]
F22806
PC-2
PAINT COATING
[Sedan]
F24801-1
PAINT COATING
2.
PC-3
INSIDE
[Hatchback]
F22336
PC-4
PAINT COATING
[Sedan]
F24802-1
PAINT COATING
3.
PC-5
OUTSIDE
[Hatchback]
F22337
PC-6
PAINT COATING
[Sedan]
F24803-1
PAINT COATING
4.
PC-7
DOOR PARTS
[Hatchback 3 Door]
F22338
PC-8
PAINT COATING
[Hatchback 5 Door]
F23339
PAINT COATING
PC-9
[Sedan]
F24804-1
PC-10
PAINT COATING
[Hatchback]
F22810
PAINT COATING
PC-11
[Sedan]
F24805-1
PAINT COATING
PC-12
BODY PANEL UNDER COATING AREAS
HINT:
1) First wipe off any dirt, grease or oil with a rag soaked in silicone remover.
2) Cover the surrounding areas with masking paper to avoid coating unnecessary areas. If other areas are accidently coated, wipe off the coating immediately.
3) Apply the first coating of undercoat to all welded areas and panel joints, then apply a second coat over the
entire area.
4) Do not coat parts which become hot such as the tailpipe, and moving parts such as the propeller shaft.
5) Apply under coating to all weld points under the body to ensure corrosion prevention at every location except
the areas below.
6) Be sure to seal the edge of the flange of the member and bracket with undercoating.
7) Be sure to repair the under coating as necessary if there are signs of damage such as cracking or peeling.
8) Apply sealer before applying the under coat for rust prevention.
[Hatchback]
[LH]
[RH]
F23340
POINT
1
The film thickness of the interior portion of the rear wheel housing should be 1.0 mm (0.04 in.) or more for the
front half and 2.0 mm (0.08 in.) of more for the rear half.
REFERENCE
The under coating should be applied according to the specifications for your country while referring to the
notes above.
PAINT COATING
PC-13
[Sedan]
[LH]
[RH]
F24806-1
POINT
1
The film thickness of the interior portion of the rear wheel housing should be 1.0 mm (0.04 in.) or more for the
front half and 1.3 mm (0.05 in.) of more for the rear half.
REFERENCE
The under coating should be applied according to the specifications for your country while referring to the
notes above.
PC-14
PAINT COATING
FOAMED MATERIAL APPLICATION AREAS
The sections shown in the figure below are filled with foamed material to provide noise insulation.
Refill with foamed materials after repairing these sections and their surrounding sections.
HINT:
1) Use the service holes located on the reverse side of the body panel to refill foamed materials.
2) Follow manufacturer directions when handling the foamed material.
[Hatchback]
[5 Door Only]
F23341
PAINT COATING
PC-15
[Sedan]
F24808-1
PC-16
PAINT COATING
BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION AREAS
HINT:
1) Apply anti-rust agent (wax) around the hinges whenever adjusting the doors and hoods.
2) Even if partially repairing a part, apply anti-rust agent (wax) over the entire application area of the part.
3) Wipe off the anti-rust agent immediately with a rag soaked in silicone remover if it is accidentally applied to
other areas.
[Hatchback]
F23344
PAINT COATING
PC-17
[Sedan]
F24809-1
PAINT COATING
PC-18
SILENCER SHEET INSTALLATION AREAS
[Sedan]
F24810-1
0.8 mm (0.031 in.)
BODY PANEL REPLACEMENT
BP-10
FRONT SIDEMEMBER REINFORCEMENT
(CUT-P)
REPLACEMENT
With the radiator support removed.
F22825A
REMOVAL
[LH]
140 mm
65 mm
F23301
POINT
1
Remove [A] at the same time.
PART NAME
[A] Front Sidemember Outer Plate
65 mm (2.56 in.)
140 mm (5.51 in.)
BODY PANEL REPLACEMENT
BP-11
[RH]
70 mm
140 mm
F23302
POINT
1
Remove [B] before conducting this work.
2
Remove [A] at the same time.
PART NAME
[B] Engine Front Mounting Bracket
[A] Front Sidemember Outer Plate
70 mm (2.76 in.)
140 mm (5.51 in.)
BODY PANEL REPLACEMENT
BP-12
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
[LH]
F23303
PART NAME
[A] Front Sidemember Outer Plate
BODY PANEL REPLACEMENT
BP-13
[RH]
F23304
POINT
1
Remove the [B] from the new parts of the front sidemember reinforcement.
2
After installing the new parts, install [B].
PART NAME
[A] Front Sidemember Outer Plate
[B]
Engine Front Mounting Bracket
PAINT COATING
PC-19
BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS
HINT:
[Sedan]
1)
Anti-chipping paint should be applied to some areas before the second coat and to other areas after the top
coat.
2) Wipe off the paint immediately with a rag soaked in silicone remover if unrelated areas are accidentally coated.
[Hatchback]
F24811-1
PVC
Protection
Tape
PVC
Adheshion Primer
Urethane
—
Soft−Chip (Poly
— Olefine)
—
—
F23342
PC-20
MEMO
PC-21
MEMO
BODY DIMENSIONS
DI-3
BODY DIMENSION DRAWINGS
ENGINE COMPARTMENT
Hatchback
(Three-Dimensional Distance)
1,373
(54.06)
745
(29.33)
1,361
(53.58)
690
(27.17)
576
(22.68)
1,261
(49.65)
620
(24.41)
1,131
(44.53)
572
(22.52)
646
(25.43)
1,433
(56.42)
749
(29.49)
1,026
(40.39)
1,126
(44.33)
1,047
(41.22)
680
(26.77)
766
(30.16)
584
(22.99)
944
(37.17)
957
(37.68)
937
(36.89)
262
(10.31)
846
(33.31)
Vehicle Dimensions
Height from Imaginary Standard Line
A-a
A-C
or
a-c
B-C
or
b-c
B-c
or
b-C
B-K
or
b-k
B-k
or
b-K
K-k
A, a
C, c
G, g
1,324
(52.13)
170
(6.69)
209
(8.23)
1,261
(49.65)
564
(22.20)
942
(37.09)
505
(19.88)
810
(31.89)
815
(32.09)
614
(24.17)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
Hole dia.
Symbol
mm (in.)
Name
Hole dia.
A, a
Front fender installation nut
M6 (0.24)
G, g
Headlight bracket standard hole
B, b
Front spring support hole−inner
ø 11 (0.43)
H, h
Radiator side support installation hole
C, c
Hood hinge installation nut-rear
M8 (0.31)
I, i
Radiator seal installation hole
ø 9 (0.35)
—
J, j
Front fender mounting bracket standard hole
ø 10 (0.39)
Front bumper installation hole
ø 7 (0.28)
D
Cowl panel center mark
E, e
Front side member standard hole
ø 15 (0.59)
K, k
F, f
Front side member standard hole
ø 10 (0.39)
—
—
ø 10 (0.39)
ø 6.3 (0.248)
—
BODY DIMENSIONS
DI-4
BODY DIMENSION DRAWINGS
ENGINE COMPARTMENT
Sedan
(Three-Dimensional Distance)
1,374
(54.09)
767
(30.20)
1,376
(54.17)
178
(7.01)
692
(27.24)
1,347
(53.03)
738
(29.06)
665
(26.18)
509
(20.04)
1,205
(47.44)
684
(26.93)
704
(27.72)
1,336
(52.60)
1,279
(50.35)
1,047
(41.22)
1,433
(56.42)
1,408
567
(22.32) (55.43)
1,098
(43.23)
743
(29.25)
1,008
(39.69)
1,126
(44.33)
820
(32.28)
597
(23.50)
567
(22.32)
950
(37.40)
957
(37.68)
937
(36.89)
262
(10.31)
846
(33.31)
Vehicle Dimensions
Height from imaginary standard line
B-C
or
b-c
B-c
or
b-C
B-D
or
b-D
B-K
or
b-k
B-k
or
b-K
C-L
or
c-l
A, a
C, c
G, g
223
(8.78)
1,264
(49.76)
575
(22.64)
998
(39.29)
597
(23.50)
381
(15.00)
778
(30.63)
792
(31.18)
615
(24.21)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
Hole dia.
Symbol
mm (in.)
Name
Hole dia.
9 (0.35)
A, a
Front fender installation nut
M6 (0.24)
G, g
Headlight bracket installation hole
B, b
Front spring support hole-inner
ø11 (0.43)
H, h
Radiator side support inatallation hole
C, c
Hood hinge installation nut-rear
M8 (0.31)
I, i
Radiator seal installation hole
ø9 (0.35)
—
J, j
Front fender mounting bracket standard hole
ø10 (0.39)
D
Cowl panel center mark
ø6.3 (0.248)
E, e
Front side member standard hole
ø15 (0.59)
K, k
Radiator upper support standard hole
ø13 (0.51)
F, f
Front side member standard hole
ø10 (0.39)
L, l
Front fender installation nut
M6 (0.24)
BODY DIMENSIONS
DI-5
BODY OPENING AREAS (Side View)
Hatchback 3 Door
(Three-Dimensional Distance)
1,050
(41.34)
903
(35.55)
663
(26.10)
1,502
(59.13)
982
(38.66)
1,373
(54.06)
894
(35.20)
1,239
(48.78)
1,085
(42.72)
1,266
(49.84)
1,060
(41.73)
1,145
(45.08)
Vehicle Dimensions
E-e
F-f
G-g
H-h
I-i
J-j
K-k
1,147
(45.16)
1,379
(54.29)
1,417
(55.79)
1,417
(55.79)
1,090
(42.91)
1,258
(49.53)
1,395
(54.92)
E-f
or
e-F
E-h
or
e-H
E-j
or
e-J
E-k
or
e-K
F-j
or
f-J
F-k
or
f-K
G-h
or
g-H
H-i
or
h-I
J-k
or
j-K
1,532
(60.31)
1,609
(63.35)
1,372
(54.02)
1,549
(60.98)
1,826
(71.89)
1,745
(68.70)
1,440
(56.69)
1,650
(64.96)
1,429
(56.26)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
mm (in.)
Name
Hole dia.
Symbol
Name
A, a
Roof panel corner
—
G, g
Rocker panel assembly mark
—
B, b
Hood hinge installation nut
M8 (0.31)
H, h
Rocker panel assembly mark
—
C, c
Front door hinge installation nut
M8 (0.31)
I, i
Roof side rail assembly mark
—
D, d
Front door hinge installation nut
M8 (0.31)
J, j
Quarter panel assembly mark
—
E, e
Front body pillar assembly mark
—
K, k
Quarter panel assembly mark
—
F, f
Front body pillar assembly mark
—
—
—
Hole dia.
—
BODY DIMENSIONS
DI-6
BODY OPENING AREAS (Side View: Front)
Hatchback 5 Door
(Three-Dimensional Distance)
1,050
(41.34)
903
(35.55)
522
(20.55)
1,502
(59.13)
982
(38.66)
1,085
(42.72)
1,373
(54.06)
1,062
(41.81)
761
(29.96)
1,147
(45.16)
856
(33.70)
999
(39.33)
Vehicle Dimensions
E-e
F-f
G-g
H-h
I-i
J-j
K-k
1,147
(45.16)
1,379
(54.29)
1,417
(55.79)
1,417
(55.79)
1,090
(42.91)
1,263
(49.72)
1,391
(54.76)
E-f
or
e-F
E-h
or
e-H
E-j
or
e-J
F-j
or
f-J
F-k
or
f-K
H-i
or
h-I
I-q
or
i-Q
J-k
or
j-K
1,532
(60.31)
1,609
(63.35)
1,312
(51.65)
1,748
(68.82)
1,628
(64.09)
1,650
(64.96)
1,260
(49.61)
1,431
(56.34)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
A, a
Roof panel corner
mm (in.)
Hole dia.
Symbol
—
H, h
Rocker panel assembly mark
Name
Hole dia.
—
B, b
Hood hinge installation nut
M8 (0.31)
I, i
Roof side rail assembly mark
—
C, c
Front door hinge installation nut
M8 (0.31)
J, j
Center body pillar assembly mark
—
D, d
Front door hinge installation nut
M8 (0.31)
K, k
Center body pillar assembly mark
E, e
Front body pillar assembly mark
—
L, l
Rear door hinge installation nut
M8 (0.31)
F, f
Front body pillar assembly mark
—
M, m
Rear door hinge installation nut
M8 (0.31)
G, g
Rocker panel assembly mark
—
Q, q
Roof side rail assembly mark
—
—
BODY DIMENSIONS
DI-7
BODY OPENING AREAS (Side View: Rear)
Hatchback 5 Door
(Three-Dimensional Distance)
723
(28.46)
905
(35.63)
973
1,076 (38.31)
(42.36)
846
(33.31)
815
(32.09)
598
(23.54)
Vehicle Dimensions
N-n
O-o
P-p
Q-q
R-r
S-s
1,263
(49.72)
1,381
(54.37)
1,417
(55.79)
1,068
(42.05)
1,130
(44.49)
1,405
(55.31)
G-p
or
g-P
N-r
or
n-R
N-s
or
n-S
O-r
or
o-R
O-s
or
o-S
P-q
or
p-Q
R-s
or
r-S
1,717
(67.60)
1,397
(55.00)
1,578
(62.13)
1,584
(62.36)
1,516
(59.69)
1,634
(64.33)
1,451
(57.13)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
Hole dia.
Symbol
mm (in.)
Name
Hole dia.
G, g
Rocker panel assembly mark
—
Q, q
Roof side rail assembly mark
—
N, n
Center body pillar assembly mark
—
R, r
Quarter panel assembly mark
—
O, o
Center body pillar assembly mark
—
S, s
Quarter panel assembly mark
—
P, p
Quarter panel assembly mark
—
—
—
—
BODY DIMENSIONS
DI-8
BODY OPENING AREAS (Side View: Front)
Sedan
(Three-Dimensional Distance)
1,044
(41.10)
914
(35.98)
1,507
(59.33)
1,374
(54.09)
853
(33.58)
885
(34.84)
867
(34.13)
946
(37.24)
1,173
(46.18)
1,112
(43.78)
1,064
(41.89)
918
(36.14)
1,040
(40.94)
1,069
(42.09)
Vehicle Dimensions
E-e
F-f
G-g
H-h
I-i
J-j
K-k
L-l
1,266
(49.84)
1,378
(54.25)
1,418
(55.83)
1,418
(55.83)
1,128
(44.41)
1,240
(48.82)
1,378
(54.25)
1,480
(58.27)
E-f
or
e-F
E-h
or
e-H
E-j
or
e-J
F-j
or
f-J
F-k
or
f-K
H-i
or
h-I
J-k
or
j-K
1,443
(56.81)
1,596
(62.83)
1,515
(59.65)
1,756
(69.13)
1,656
(65.20)
1,579
(62.17)
1,403
(55.24)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
A, a
Roof panel corner
mm (in.)
Hole dia.
Symbol
—
H, h
Rocker panel assembly mark
Name
Hole dia.
—
B, b
Hood hinge installation nut
M8 (0.31)
I, i
Roof side rail assembly mark
—
C, c
Front door hinge installation nut
M8 (0.31)
J, j
Center body pillar assembly mark
—
D, d
Front door hinge installation nut
M8 (0.31)
K, k
Center body pillar assembly mark
E, e
Front body pillar assembly mark
—
L, l
Front door lock striker installation nut
M8 (0.31)
F, f
Front body pillar assembly mark
—
M, m
Rear door hinge installation nut
M8 (0.31)
G, g
Rocker panel assembly mark
—
N, n
Rear door hinge installation nut
M8 (0.31)
—
BODY DIMENSIONS
DI-9
BODY OPENING AREAS (Side View: Rear)
Sedan
(Three-Dimensional Distance)
736
(28.98)
863
827
(33.98) (32.56)
915
(36.02)
896
(35.28) 1,000
904
(35.59)
(39.37)
641
(25.24)
1,009
(39.72)
Vehicle Dimensions
O-o
P-p
Q-q
R-r
S-s
T-t
U-u
1,240
(48.82)
1,373
(54.06)
1,418
(55.83)
1,084
(42.68)
1,197
(47.13)
1,405
(55.31)
1,489
(58.62)
G-q
or
g-Q
I-r
or
i-R
O-s
or
o-S
O-t
or
o-T
P-t
or
p-T
Q-r
or
q-R
S-t
or
s-T
1,770
(69.69)
1,375
(54.13)
1,424
(56.06)
1,577
(62.09)
1,529
(60.20)
1,593
(62.72)
1,430
(56.30)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
Hole dia.
Symbol
mm (in.)
Name
Hole dia.
G, g
Rocker panel assembly mark
—
Q, q
Rocker panel assembly mark
—
I, i
Roof side rail assembly mark
—
R, r
Roof side rail assembly mark
—
M, m
Rear door hinge installation nut
M8 (0.31)
S, s
Quarter panel assembly mrak
—
N, n
Rear door hinge installation nut
M8 (0.31)
T, t
Quarter panel assembly mark
—
O, o
Center body pillar assembly mark
—
U, u
Rear door lock striker installation nut
P, p
Center body pillar assembly mark
—
—
—
M8 (0.31)
—
BODY DIMENSIONS
DI-11
BODY OPENING AREAS (Rear View)
Hatchback 5 Door
(Three-Dimensional Distance)
1,624
(63.94)
1,020
(40.16)
1,122
(44.17)
441
(17.36)
1,247
(49.09)
1,152
907 (45.35)
(35.71)
725
(28.54)
917
(36.10)
1,333
(52.48)
1,090
(42.91)
649
(25.55) 1,103
678
(26.69)
410
(16.14)
(43.43)
787
(30.98)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
A, a
Back door hinge installation hole
B, b
Back door stay installation nut
C, c
Back door opening trough standard hole
D, d
Back door opening trough/Body lower back
panel adjoining point
mm (in.)
Hole dia.
Symbol
Name
ø 10.2 (0.402): RH
ø 10.2 (0.402) 12 (0.47): LH
E, e
Back door lock striker installation nut
M6 (0.24)
F, f
Rear shock absorber installation hole−inner
ø 10 (0.39)
G, g
Center body pillar assembly mark
—
—
—
Hole dia.
—
M8 (0.31)
ø 18 (0.71)
—
BODY DIMENSIONS
DI-10
BODY OPENING AREAS (Rear View)
Hatchback 3 Door
(Three-Dimensional Distance)
1,793
(70.59)
1,020
(40.16)
1,423
(56.02)
1,247
(49.09)
441
(17.36)
1,152
917
(36.10) (45.35) 725
(28.54)
907
(35.71)
1,103
(43.43)
1,333
(52.48)
1,090
(42.91)
678
(26.69)
649
(25.55)
410
(16.14)
787
(30.98)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
A, a
Back door hinge installation hole
B, b
Back door stay installation nut
C, c
Back door opening trough standard hole
D, d
Back door opening trough/Body lower back
panel adjoining point
mm (in.)
Hole dia.
Symbol
Name
ø 10.2 (0.402): RH
ø 10.2 (0.402) 12 (0.47): LH
E, e
Back door lock striker installation nut
M6 (0.24)
F, f
Rear shock absorber installation hole−inner
ø 10 (0.39)
G, g
Roof side rail assembly mark
—
—
—
Hole dia.
M8 (0.31)
ø 18 (0.71)
—
—
BP-14
BODY PANEL REPLACEMENT
FRONT SIDEMEMBER REINFORCEMENT
(ASSY)
REPLACEMENT
With the radiator support and front fender apron removed.
F22829A
REMOVAL
F22829
POINT
1
Remove [A] at the same time.
PART NAME
[A] Front Sidemember Outer Plate
BODY PANEL REPLACEMENT
BP-15
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F22830
POINT
1
Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front
wheel alignment.
BODY PANEL REPLACEMENT
BP-16
[LH]
[RH]
F22831
PART NAME
[A] Front Sidemember Outer Plate
BODY DIMENSIONS
DI-12
BODY OPENING AREAS (Rear View)
Sedan
(Three-Dimensional Distance)
1,007
(39.65)
550
(21.65)
1,215
(47.83)
1,636
(64.41)
1,166
(45.91)
1,150
(45.28)
1,135
(44.69)
1,053
(41.46)
441
(17.36)
1,011
(39.80)
1,090
(42.91)
1,196
(47.09)
743
(29.25)
1,432
(56.38)
805
(31.69)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
Hole dia.
Symbol
mm (in.)
Name
Hole dia.
A, a
Roof panel corner
—
E, e
Quarter panel standard hole
B, b
Upper back panel corner
—
F, f
Body lower back reinforcement corner
ø13 (0.51)
—
C, c
Back door opening trough corner
—
G, g
Rear shock absorber installation hole
ø18 (0.71)
D, d
Luggage door opening front trough corner
—
H, h
Center body pillar assembly mark
—
BODY DIMENSIONS
DI-13
UNDER BODY
Hatchback
(Three-Dimensional Distance)
598
(23.54)
453
(17.83)
RH
536
276
796 (10.87)
(21.10)
(31.34)
844
(33.23) 796
(31.34)
727
759
854
(28.62)
(29.88)
637
(33.62)
(25.08)
1,100
(43.31)
645
768
478
(25.39)
(30.24) (18.82)
991
(39.02)
1,096
(43.15)
1,068
(42.05)
LH
410
(16.14)
1,120
(44.09)
1,060
(41.73)
1,266
(49.84)
920
(36.22)
1,228
(48.35)
1,085
(42.72)
453
(17.83)
415
(16.34)
1,231
(48.46)
1,096
(43.15)
872
(34.33)
967
930
(38.07) (36.61)
957
(37.68)
795
(31.30)
998
(39.29)
1,331
(52.40)
979
(38.54)
462
(18.19)
310
(12.20)
653
(25.71)
Front
A, a
B, b
C, c
152
396
304
(5.98) (15.59) (11.97)
D, d E, e F, f
243 141
54
(9.57) (5.55) (2.13)
G-g
1
2
3
390
(15.35)
100
(3.94)
100
(3.94)
100
(3.94)
G, g H, h
75
51
(2.95) (2.01)
I, i
56
(2.20)
J, j K, k L, l
98 137 276
(3.86) (5.39) (10.87)
M, m
271
(10.67)
N, n
288
(11.34)
Imaginary
Standard
Line
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Hole dia.
Symbol
A, a
Radiator side support installation nut
Name
M6 (0.24)
H, h
mm (in.)
Name
Hole dia.
Front side member standard hole
ø 18 (0.71)
B, b
Radiator side support installation hole
ø 6.3 (0.248)
I, i
Front floor pan standard hole
ø 18 (0.71)
C, c
Front side member standard hole
ø 18 (0.71)
J, j
Floor side inner rear member standard hole
ø 18 (0.71)
D, d
Front suspension installation nut
M12 (0.47)
K, k
Rear axle beam installation outer hole-inner
ø 15 (0.59)
E, e
Front suspension installation nut
M14 (0.55)
L, l
Rear floor side member standard hole
ø 18 (0.71)
F, f
Torque box front standard hole
ø 25 (0.98)
M, m
Rear spring plate standard hole
ø 18 (0.71)
G, g
Front floor pan standard hole
ø 18 (0.71)
N, n
Rear floor side member standard hole
ø 18 (0.71)
BODY DIMENSIONS
DI-14
UNDER BODY
Sedan
(Three-Dimensional Distance)
855
(33.66)
957
(37.68)
RH
LH
453
(17.83)
825
(32.48)
643
(25.31)
872
(34.33)
991
(39.02)
440
893
(17.32)
(35.16)
930
(36.61)
1,068
(42.05)
415
(16.34)
869
(34.21)
796
(31.34) 276
(10.87)
536
(21.10)
768
(30.24)
796
(31.34)
390
727
(28.62) (15.35)
854
(33.62)
759
844 (29.88)
(33.23)
645
(25.39)
1,100
(43.31)
478
(18.82)
1,182
(46.54)
1,341
(52.80)
410
(16.14)
1,141
(44.92)
453
(17.83)
1,227
(48.31)
950
(37.40)
1,231
(48.46)
979
(38.54)
1,331
(52.40)
462
(18.19)
653
(25.71)
1,318
(51.89)
1,060
(41.73)
1,156
(45.51)
638
(25.12)
Vehicle Dimensions
C-f
or
c-F
F-h
or
f-H
G-h
or
g-H
1
2
3
1,305
(51.38)
1,065
(41.93)
637
(25.08)
100
(3.94)
100
(3.94)
100
(3.94)
Front
A,a B,b
C,c
138 396
304
(5.43)(15.59) (11.97)
D,d
E,e
F,f
243
141
54
(9.57) (5.55) (2.13)
G,g H,h
75
51
(2.95) (2.01)
1
J,j K,k
M,m
98 137
269
(3.86) (5.39) (10.59)
L,l
3
276
(10.87)
I,i
56
(2.20)
2
N,n
269
(10.59)
Imaginary
Standard
Line
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Hole dia.
Symbol
A, a
Radiator lower support standard hole
Name
ø18 (0.71)
H, h
mm (in.)
Name
Hole dia.
Front side member standard hole
ø18 (0.71)
B, b
Radiator side support inatallation hole
ø6.3 (0.248)
I, i
Front floor pan standard hole
ø18 (0.71)
C, c
Front side member standard hole
ø18 (0.71)
J, j
Floor side inner rear member standard hole
ø18 (0.71)
D, d
Front suspension member installation nut
M12 (0.47)
K, k
Rear axle beam installation outer hole-inner
ø15 (0.59)
E, e
Front suspension member installation nut
M14 (0.55)
L, l
Rear floor side member standard hole
ø18 (0.71)
F, f
Torque box front standard hole
ø25 (0.98)
M, m
Rear spring plate standard hole
ø18 (0.71)
G, g
Front floor pan standard hole
ø18 (0.71)
N, n
Rear floor side member standard hole
ø18 (0.71)
BODY DIMENSIONS
DI-15
UNDER BODY
Hatchback
(Two-Dimensional Distance)
1,887 1,707
(74.29) (67.20)
1,271
(50.04)
925
(36.42)
RH
484
465
(19.06) (18.31)
490
(19.29)
1,149
(45.24)
665
(26.18)
550
(21.65)
614
(24.17)
646
822
(25.43) (32.36)
0
546
(21.50)
530
(20.87)
422
(16.61)
205
(8.07)
479
(18.86)
436
(17.17)
1,781
(70.12)
1,298
(51.10)
195
(7.68)
384
(15.12)
205
(8.07)
614
(24.17)
LH
Front
Wheel Base
0
645
(25.39)
1,080
(42.52)
2,460 (96.85)
A, a B, b C, c
E, e D, d F, f G, g
152 396 304
734
243 141 54
(5.98) (15.59) (11.97) (28.90) (9.57) (5.55) (2.13)
718
(28.27)
1
2
3
100
(3.94)
100
(3.94)
100
(3.94)
H, h I, i
75
51
(2.95) (2.01)
J, j
56
(2.20)
K, k
98
(3.86)
489
(19.25)
460
(18.11)
1,037
(40.83)
1,345
(52.95)
M, m N, n O, o
P, p
276
271
607
288
(10.87) (10.67) (23.90) (11.34)
L, l
137
(5.39)
Imaginary
Standard
Line
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
Hole dia.
Symbol
mm (in.)
Name
Hole dia.
A, a
Radiator side support installation nut
M6 (0.24)
I, i
Front side member standard hole
ø 18 (0.71)
B, b
Radiator side support installation hole
ø 6.3 (0.248)
J, j
Front floor pan standard hole
ø 18 (0.71)
C, c
Front side member standard hole
ø 18 (0.71)
K, k
Floor side inner rear member standard hole
ø 18 (0.71)
D, d
Front suspension member installation nut
M12 (0.47)
L, l
Rear axle beam installation outer hole-inner
ø 15 (0.59)
E, e
Front spring support plate standard hole−outer
ø 11 (0.43)
M, m
Rear floor side member standard hole
ø 18 (0.71)
F, f
Front suspension member installation nut
M14 (0.55)
N, n
Rear spring plate standard hole
ø 18 (0.71)
G, g
Torque box front standard hole
ø 25 (0.98)
O, o
Rear shock absorber installation hole
ø 18 (0.71)
H, h
Front floor pan standard hole
ø 18 (0.71)
P, p
Rear floor side member standard hole
ø 18 (0.71)
BODY DIMENSIONS
DI-16
UNDER BODY
Sedan
(Two-Dimensional Distance)
1,895 1,707
(74.61) (67.20)
465
(18.31)
RH
220
(8.66)
LH
1,271
(50.04)
925
(36.42)
490
(19.29)
550
(21.65)
614
(24.17)
479
(18.86)
384
436
(17.17) (15.12)
1,781
(70.12)
1,298 1,080
(51.10) (42.52)
0
422
(16.61)
665
(26.18) 530
(20.87)
546
(21.50)
205
(8.07)
614
(24.17)
645
(25.39)
808
(31.81)
0
F,f G,g
141 54
(5.55) (2.13)
E,e
734
(28.90)
H,h
I,i
75
51
(2.95) (2.01)
1
489
(19.25)
475
(18.70)
1,127
(44.37)
1,765
(69.49)
1
2
3
100
(3.94)
100
(3.94)
100
(3.94)
2,460 (96.85)
Front
D,d
243
(9.57)
1,239
(48.78)
205
(8.07)
195
(7.68)
Wheel Base
A,a B,b
C,c
138 396
304
(5.43) (15.59) (11.97)
736
912
(28.98) (35.91)
N,n
O,o
K,k L,l
269
607
98 137
(3.86) (5.39) (10.59) (23.90)
J,j
56
(2.20)
2
3
M,m
276
(10.87)
P,p
269
(10.59)
Imaginary
Standard
Line
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
Hole dia.
Symbol
mm (in.)
Name
Hole dia.
A, a
Radiator lower support standard hole
ø18 (0.71)
I, i
Front side member standard hole
ø18 (0.71)
B, b
Radiator side support inatallation hole
ø6.3 (0.248)
J, j
Front floor pan standard hole
ø18 (0.71)
C, c
Front side member standard hole
ø18 (0.71)
K, k
Floor side inner rear member standard hole
ø18 (0.71)
D, d
Front suspension member installation nut
M12 (0.47)
L, l
Rear axle beam installation outer hole-inner
ø15 (0.59)
E, e
Front spring support plate standard hole
ø11 (0.43)
M, m
Rear floor side member standard hole
ø18 (0.71)
F, f
Front suspension member installation nut
M14 (0.55)
N, n
Rear spring plate standard hole
ø18 (0.71)
G, g
Torque box front standard hole
ø25 (0.98)
O, o
Rear shock absorber installation hole
ø18 (0.71)
H, h
Front floor pan standard hole
ø18 (0.71)
P, p
Rear floor side member standard hole
ø18 (0.71)
BODY DIMENSIONS
DI-17
REFERENCE VALUE
ENGINE COMPARTMENT
Hatchboack
(Three-Dimensional Distance)
1,324
(52.13)
1,361
(53.58)
618
(24.33)
1,025
(40.35)
1,008
(39.69)
590
(23.23)
505
(19.88)
C-c
C-D
or
c-d
1,324
(52.13)
38
(1.50)
HINT: These values are actual measurements made on a vehicle.
Use these reference values.
Symbol
Name
Hole dia.
Symbol
mm (in.)
Name
Hole dia.
A, a
Front bumper cover installation bolt
—
C, c
Headlight installation bolt
—
B, b
Front end of fender
—
D, d
Front fender installation bolt
—
BODY DIMENSIONS
DI-18
REFERENCE VALUE
ENGINE COMPARTMENT
Sedan
(Three-Dimensional Distance)
234
(9.21)
1,347
(53.03)
1,357
(53.43)
533
(20.98)
965
(37.99)
1,357
(53.43)
1,327
(52.24)
1,070
(42.13)
1,336
(52.60)
979
(38.54)
205
(8.07)
682
(26.85)
512
(20.16)
504
(19.84)
HINT: These values are actual measurements made on a vehicle.
Use these reference values.
Symbol
Name
Hole dia.
Symbol
mm (in.)
Name
Hole dia.
A, a
Front bumper cover installation clip
—
C, c
Front fender installation bolt
—
B, b
Headlight installation bolt
—
D, d
Front fender installation bolt
—
BODY DIMENSIONS
DI-19
UNDER BODY
(Two-Dimensional Distance)
Radiator support installation
4 M10 NUT
11
15
25.0
142.6
2.3
11
15
2.3
1.6
Front spring support
2 11
52
2.8
0.6
51.2
63.6 34.1
Rear shock absorber installation
2.3
2.0
4.9
20.6
5.5
13.6
2.0
mm
BODY PANEL REPLACEMENT
BP-17
COWL TOP SIDE PANEL (ASSY)
REPLACEMENT
F22832A
REMOVAL
F22832
BP-18
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
(20 mm)
(25 mm)
(30 mm)
(15 mm)
F22833
15 mm (0.59 in.)
20 mm (0.79 in.)
25 mm (0.98 in.)
30 mm (1.18 in.)
BODY PANEL REPLACEMENT
BP-19
COWL TOP SIDE UPPER PANEL (ASSY)
REPLACEMENT
With the cowl top side panel removed.
F22834A
REMOVAL
F22834
BP-20
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
(25 mm)
(25 mm)
F22835
POINT
1
Inspect the fitting of the hood and related parts before welding as this affects the appearance of the finish.
25 mm (0.98 in.)
BODY PANEL REPLACEMENT
BP-21
FRONT BODY PILLAR (CUT)
REPLACEMENT
With the cowl top side upper panel removed.
F22836A
REMOVAL
100 mm
80 mm
160 mm
70 mm
F22836
POINT
1
*1: This part of the outer panel is reused because the rocker panel section is cut off at a position behind the
service part cut position of the outer panel.
70 mm (2.76 in.)
80 mm (3.15 in.)
100 mm (3.94 in.)
160 mm (6.30 in.)
BP-22
BODY PANEL REPLACEMENT
F22837
BODY PANEL REPLACEMENT
BP-23
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
spots.
230 mm
(10 mm 3)
(15 mm 3)
F22838
POINT
1
Before temporarily installing the new parts, weld [A], [B], [C] and [D] with standard welding number.
PART NAME
[B] Front Body Pillar Lower Reinforce
[A] Rocker Outer Reinforce
[D] Front Body Outer Pillar
[C] Front Body Inner Pillar
10 mm (0.39 in.)
15 mm (0.59 in.)
230 mm (9.06 in.)
BP-24
BODY PANEL REPLACEMENT
(10 mm)
(15 mm 2)
F22839
POINT
1
Inspect the fitting of the front fender, front door, windshield glass and other related parts before welding as this
affects the appearance of the finish.
10 mm (0.39 in.)
15 mm (0.59 in.)
BODY PANEL REPLACEMENT
BP-25
CENTER BODY PILLAR (CUT): 5-Door
REPLACEMENT
F22840A
REMOVAL
50 mm
30 mm
30 mm
50 mm
50 mm
F22840
30 mm (1.18 in.)
50 mm (1.97 in.)
BODY PANEL REPLACEMENT
BP-26
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
80 mm
45 mm
(10 mm 7)
F22841
POINT
1
Before temporarily installing the new parts, weld [A], [B] and [C] with standard welding number.
PART NAME
[B] Center Body Pillar Reinforcement
[A] Rocker Outer Reinforce
10 mm (0.39 in.)
45 mm (1.77 in.)
80 mm (3.15 in.)
[C]
Center Body Inner Pillar
BODY PANEL REPLACEMENT
BP-27
(10 mm 4)
F22842
POINT
1
Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appearance of the finish.
2
After welding [A], [B] and [C] to the vehicle, install [D].
PART NAME
[A] Rocker Outer Reinforce
[C] Center Body Inner Pillar
10 mm (0.39 in.)
[B]
[D]
Center Body Pillar Reinforcement
Center Body Outer Pillar
BP-28
BODY PANEL REPLACEMENT
FRONT DOOR OUTER PANEL (CUT): 3-Door
REPLACEMENT
F23305A
REMOVAL
Hemming Location
Disc Sander
F23305
POINT
1
After grinding off the hemming location, remove the outer panel.
BODY PANEL REPLACEMENT
BP-29
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
10 mm
Do not close
the drain hole.
Cloth Tape
30
Hemming Tool
F23306
POINT
1
Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection
beam and backside of the new parts.
HINT:
1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer
panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact.
2
Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool.
HINT:
1) Perform hemming in three steps, being careful not to warp the panel.
2) If a hemming tool cannot be used, hem with a hammer and dolly.
BP-30
BODY PANEL REPLACEMENT
FRONT DOOR OUTER PANEL (CUT): 5-Door
REPLACEMENT
F23307A
REMOVAL
Hemming Location
Disc Sander
F23307
POINT
1
After grinding off the hemming location, remove the outer panel.
BODY PANEL REPLACEMENT
BP-31
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
10 mm
Do not close
the drain hole.
Cloth Tape
30
Hemming Tool
F23308
POINT
1
Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection
beam and backside of the new parts.
HINT:
1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer
panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact.
2
Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool.
HINT:
1) Perform hemming in three steps, being careful not to warp the panel.
2) If a hemming tool cannot be used, hem with a hammer and dolly.
BP-32
BODY PANEL REPLACEMENT
REAR DOOR OUTER PANEL (CUT): 5-Door
REPLACEMENT
F23309A
REMOVAL
Hemming Location
Disc Sander
F23309
POINT
1
After grinding off the hemming location, remove the outer panel.
BODY PANEL REPLACEMENT
BP-33
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
10 mm
Do not close the
drain hole.
Cloth Tape
30
Hemming Tool
F23310
POINT
1
Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection
beam and backside of the new parts.
HINT:
1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer
panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact.
2
Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool.
HINT:
1) Perform hemming in three steps, being careful not to warp the panel.
2) If a hemming tool cannot be used, hem with a hammer and dolly.
BP-34
BODY PANEL REPLACEMENT
ROCKER OUTER PANEL (CUT-H): 5-Door
REPLACEMENT
F22843A
REMOVAL
380 mm
F22843
380 mm (14.96 in.)
BODY PANEL REPLACEMENT
BP-35
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F22844
POINT
1
Inspect the fitting of the front door and other related parts before welding as this affects the appearance of the
finish.
BP-36
BODY PANEL REPLACEMENT
ROCKER OUTER PANEL (CUT): 3-Door
REPLACEMENT
F23311A
REMOVAL
F23311
BODY PANEL REPLACEMENT
BP-37
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F23312
POINT
1
Inspect the fitting of the front door and other related parts before welding as this affects the appearance of the
finish.
BP-38
BODY PANEL REPLACEMENT
ROCKER OUTER PANEL (CUT): 5-Door
REPLACEMENT
F22845A
REMOVAL
100 mm
F22845
100 mm (3.94 in.)
BODY PANEL REPLACEMENT
BP-39
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F22846
POINT
1
Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appearance of the finish.
BODY PANEL REPLACEMENT
BP-40
Adhesive Application Area Work
Procedure
NOTE
This vehicle has areas on the Quarter Panel and Quarter
Wheel Housing Outer Panel that are joined together only
with adhesive. It is necessary to conduct the correct repair
procedures for high durability so make sure to follow the
instructions below for the adhesive application areas.
Type of adhesive used: 3M8115 Auto Mix Panel Bond
1.
Adhesive Application Area
Cut and Join
Location
Removal of the Quarter Panel
(A) Remove the body sealer from the Quarter Panel and cut at
the cut and join location. Remove the spot welded portions.
(B) After rough cutting the Wheel Arch portion, heat the adhesive applied area and remove the panel. {Heat the Wheel
Arch portion of the Quarter Panel at 110 to 140C (230 to
284F) with a dryer or gas burner and remove the Quarter
Panel.}
Spot Weld
Cut and Join Location
010L23a
2.
010L06
Removal of the previous adhesive coating
(A) Heat at 110 to 140C (230 to 284F) with a dryer or gas
burner.
(B) Scrape away the adhesive with a scraper, and scuff while
sanding with a disc grinder or a belt sander.
NOTE
Make sure to use either a disc grinder or belt sander to
sand coarsely and deeply to improve adhesiveness.
Scuff at a width of approximately 10 mm (0.39 in.) over
the previous adhesive coating.
3.
Treatment of the spot welded portions on
the body
(A) After the adhesive has been removed from the body, remove the paint from the underside of the spot welded points
blow air and degrease.
(B) Apply spot sealer at the joined portion between panels.
approx.10 mm
After sanding
010L07a
BODY PANEL REPLACEMENT
4.
BP-41
Attachment of the New Quarter Panel
(A) Temporarily attach the new panel and check the fitting
condition, the cut and join locations, the welded areas, and
the adhesive applied area.
NOTE
Check the adhesive applied condition to ensure adhesive strength.
Conduct hammering to fix the non-adhered portions.
Cross-Sectional view
Adhesive
1 mm gap
010L10a
5.
Application Area
Scuffed Area
10 mm
28 mm
010L11a
Adhesive Application to New Quarter Panel
(A) Scuff with #60-120 grit sandpaper at the adhesive application area.
POINT
Sand deeply into the ED coat.
(B) Blow air around the scuffed portion and then degrease.
(C) Apply adhesive.
POINT
Apply adhesive at a width of approximately 10 mm (0.39 in.)
at a location 28 mm (1.10 in.) from the panel flange edge.
Spread the adhesive flatly within the scuffed area {approximately 10 mm (0.39 in.) in width} to remove trapped air.
010L12
Approx. 3 mm
3 mm
Adhesive
010L12-1a
010L13
BODY PANEL REPLACEMENT
BP-42
6.
010L15
Application of Adhesive to the Body
(A) Degrease the adhesive aplication area.
(B) Apply adhesive.
Refer to the diagram of step 5 for the application amount.
The application location is 7.5 mm (0.295 in.) from the
flange edge.
(C) Flatten out the applied adhesive with a spatula until it is at
an even level.
Apply adhesive at exposed metal plate portions to prevent corrosion.
It is not necessary to flatten out adhesive after it has
been reapplied.
7.5 mm
Flange Edge
010L16
010L17a
7.
Attachment of the new Quarter Panel
(A) Set the new panel in the position for temporary attachment.
(Be careful of where you hold the panel so as not to touch
the adhesive applied surfaces.)
(B) Secure in a vice grip or equivalent and check the fitting
condition.
(C) Press on the entire surface so that the adhesive between
the Quarter Panel and Quarter Wheel Housing Outer panel
becomes an even thickness.
NOTE
Be careful that adhesive that spills over does not contact
the Brake Drum.
(D) Tack weld at the cut and join welded portion.
(E) Tack weld by spot welding at one point on both ends of the
adhesive applied portions.
(F) Conduct actual welding using procedures in the BP section
of this manual.
Tack Weld
010L20a
BODY PANEL REPLACEMENT
8.
Infrared
Ray
Hearter
010L22a
BP-43
Drying
(A) Clean away adhesive that has spilled over with a degreaser
or equivalent.
(B) After all welding works have been completed, dry the adhesive with a heater.
Hardening Time
Forced drying
60C (140F) at 90 minutes.
Natural drying
24C (75F) (room temperature) for 24 hours.
9.
Other work
(A) After applying Primer Surfacer to the underside of the
Wheel Arch of the Quarter Panel, apply body sealer to the
locations indicated in the body repair manual.
Adhesive
Body Sealer
010L21a
BP-44
BODY PANEL REPLACEMENT
QUARTER PANEL (CUT): 3-Door
REPLACEMENT
F23313A
REMOVAL
205 mm
645 mm
F23313
POINT
1
*1: The hatched area indicates the adhesive application area.
PART NAME
[A] Quarter Wheel Housing Outer Panel
205 mm (8.07 in.)
645 mm (25.39 in.)
BODY PANEL REPLACEMENT
BP-45
F23314
BP-46
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
1.0 mm
F23315
POINT
1
*1: The hatched area indicates the adhesive application area.
PART NAME
[A] Quarter Wheel Housing Outer Panel
1.0 mm (0.04 in.)
[B]
Fuel Filler Opening Lid
[C]
Rivet
BODY PANEL REPLACEMENT
BP-47
F23316
POINT
1
Inspect the front door, back door, rear combination light and other related parts before welding as this affects
the appearance of the finish.
BP-48
BODY PANEL REPLACEMENT
QUARTER PANEL (CUT): 5-Door
REPLACEMENT
F22847A
REMOVAL
F23317
POINT
1
*1: The hatched area indicates the adhesive application area.
PART NAME
[A] Quarter Wheel Housing Outer Panel
BODY PANEL REPLACEMENT
BP-49
150 mm
F23318
150 mm (5.91in.)
BP-50
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
1.0 mm
F23319
POINT
1
*1: The hatched area indicates the adhesive application area.
PART NAME
[A] Quarter Wheel Housing Outer Panel
1.0 mm (0.04 in.)
[B]
Fuel Filler Opening Lid
[C]
Rivet
BODY PANEL REPLACEMENT
BP-51
F23320
POINT
1
Inspect the front door, back door, rear combination light and other related parts before welding as this affects
the appearance of the finish.
BODY PANEL REPLACEMENT
BP-52
QUARTER WHEEL HOUSING OUTER PANEL
(ASSY)
REPLACEMENT
With the quarter panel removed.
F22851A
REMOVAL
[LH]
3 Door :
5 Door :
3 Door :
5 Door :
F23321
POINT
1
After removing [A], remove the quarter wheel housing outer panel.
PART NAME
[A] Rocker Outer Extension
BODY PANEL REPLACEMENT
BP-53
[LH]
40 mm
F22852
POINT
1
After removing [B], remove the quarter wheel housing outer panel.
PART NAME
[B] Roof Side Outer Panel
40 mm (1.57 in.)
BP-54
BODY PANEL REPLACEMENT
[RH]
3 Door :
5 Door :
3 Door :
5 Door :
F23322
POINT
1
After removing [A], remove the quarter wheel housing outer panel.
PART NAME
[A] Rocker Outer Extension
BODY PANEL REPLACEMENT
BP-55
[RH]
30 mm
F22854
POINT
1
After removing [B], remove the quarter wheel housing outer panel.
PART NAME
[B] Roof Side Outer Panel
30 mm (1.18 in.)
BODY PANEL REPLACEMENT
BP-56
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
[LH]
F22856
POINT
1
After installing the new parts, install [B].
PART NAME
[B] Roof Side Outer Panel
BODY PANEL REPLACEMENT
BP-57
[LH]
3 Door :
5 Door :
3 Door :
5 Door :
F23323
POINT
1
After installing the new parts, install [A].
PART NAME
[A] Rocker Outer Extension
BODY PANEL REPLACEMENT
BP-58
[RH]
F22858
POINT
1
After installing the new parts, install [B].
PART NAME
[B] Roof Side Outer Panel
BODY PANEL REPLACEMENT
BP-59
[RH]
3 Door :
5 Door :
3 Door :
5 Door :
F23324
POINT
1
After installing the new parts, install [A].
PART NAME
[A] Rocker Outer Extension
BP-60
BODY PANEL REPLACEMENT
LOWER BACK UPPER GUSSET (ASSY)
REPLACEMENT
F22859A
REMOVAL
F22859
BODY PANEL REPLACEMENT
BP-61
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F22860
BP-62
BODY PANEL REPLACEMENT
BODY LOWER BACK PANEL (ASSY)
REPLACEMENT
F22861A
REMOVAL
F23325
BODY PANEL REPLACEMENT
BP-63
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F23326
POINT
1
Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects
the appearance of the finish.
BP-64
BODY PANEL REPLACEMENT
BACK DOOR OPENING TROUGH (ASSY)
REPLACEMENT
With the quarter panel and body lower back panel removed.
F22865A
REMOVAL
F22865
POINT
1
Remove [A] at the same time.
PART NAME
[A] Back Door Opening Lower Reinforcement
BODY PANEL REPLACEMENT
BP-65
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F22866
POINT
1
Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects
the appearance of the finish.
PART NAME
[A] Back Door Opening Lower Reinforcement
[B]
Rear Bumper Side Retainer
BP-66
BODY PANEL REPLACEMENT
QUARTER PANEL UPPER EXTENSION (CUT)
REPLACEMENT
With the back door opening trough removed.
F22867A
REMOVAL
130 mm
F22867
130 mm (5.12 in.)
BODY PANEL REPLACEMENT
BP-67
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F22868
BP-68
BODY PANEL REPLACEMENT
FLOOR SIDE RAIL FRONT PANEL (ASSY)
REPLACEMENT
With the body lower back panel removed.
F22869A
REMOVAL
F23327
BODY PANEL REPLACEMENT
BP-69
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
(10 mm 2)
F23328
10 mm ( 0.39 in.)
BODY PANEL REPLACEMENT
BP-70
REAR FLOOR PAN (ASSY)
REPLACEMENT
With the body lower back panel and floor side rail front panel removed.
F22871A
REMOVAL
[EX. U.S.A., CANADA]
F23347
BODY PANEL REPLACEMENT
BP-71
[U.S.A., CANADA]
F23345
POINT
1
After removing [A], remove the rear floor pan.
PART NAME
[A] Rear Floor Brace Braket
BODY PANEL REPLACEMENT
BP-72
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
[EX. U.S.A., CANADA]
F23348
PART NAME
[B] Spare Wheel Clamp Bracket
[C]
Actuator Cover No.3 Bracket
BODY PANEL REPLACEMENT
BP-73
[U.S.A., CANADA]
F23346
POINT
1
After installing the new parts, install [A].
PART NAME
[A] Rear Floor Brace Bracket
[D] Fuel Tube No.2 Bracket
[B] Spare Wheel Clamp Bracket
[E] Fuel Tube Bracket
BP-74
BODY PANEL REPLACEMENT
REAR FLOOR SIDE PANEL EXTENSION
(ASSY)
REPLACEMENT
With the quarter panel and body lower back panel removed.
F22875A
REMOVAL
F22875
POINT
1
After removing the rear floor side panel extension, remove [A].
PART NAME
[A] Quarter Wheel Housing Extension
BODY PANEL REPLACEMENT
BP-75
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F22876
POINT
1
After installing [A], install the new parts.
PART NAME
[A] Quarter Wheel Housing Extension
BP-76
BODY PANEL REPLACEMENT
REAR FLOOR CROSSMEMBER NO.2 (ASSY)
REPLACEMENT
F22877A
REMOVAL
F22877
BODY PANEL REPLACEMENT
BP-77
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F22878
BP-78
BODY PANEL REPLACEMENT
REAR FLOOR SIDEMEMBER (CUT)
REPLACEMENT
With the body lower back panel removed.
F22881A
REMOVAL
110 mm
40 mm
F23329
POINT
1
After removing [A], remove the rear floor sidemember.
PART NAME
[A] Floor Side Rail Front Panel
40 mm (1.57 in.)
110 mm (4.33 in.)
BODY PANEL REPLACEMENT
BP-79
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F23330
PART NAME
[A] Floor Side Rail Front Panel
BODY PANEL REPLACEMENT
BP-80
ROOF PANEL (ASSY)
REPLACEMENT
F22885A
REMOVAL
3 Door :
5 Door :
3 Door :
5 Door :
F23331
BODY PANEL REPLACEMENT
BP-81
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
3 Door :
5 Door :
3 Door :
5 Door :
F23332
POINT
1
Before temporarily installing the new parts, apply body sealer to the window shield header panel, roof panel
reinforcement and back window upper frame.
HINT:
1) Apply just enough sealer for the new parts to make contact.
BODY PANEL REPLACEMENT
BP-82
OUTER PANEL INSTALLATION TORQUE
T = 13.0 N.m
T = 11.5 N.m
T = 5.5 N.m
T = 5.5 N.m
T = 5.5 N.m
T = 5.0 N.m
T = 5.5 N.m
T = 40.0 N.m
T = 40.0 N.m
T = 5.0 N.m
T = 5.5 N.m
T = 5.0 N.m
F22801
5.0
N.m
(51
kgf.cm,
44
in..lbf)
13.0 N.m (133 kgf.cm, 10 ft..lbf)
5.5
N.m
(56
kgf.cm,
49
in..lbf)
40.0 N.m (408 kgf.cm, 30 ft..lbf)
11.5
N.m
(117
kgf.cm,
—
8
ft..lbf)
BODY PANEL REPLACEMENT
BP-83
[3 Door]
T = 26.0 N.m
T = 26.0 N.m
F23333
26.0
N.m
(265
kgf.cm,
19
ft..lbf)
—
—
BODY PANEL REPLACEMENT
BP-84
[5 Door]
T = 26.0 N.m
T = 26.0 N.m
T = 26.0 N.m
T = 26.0 N.m
F23334
26.0
N.m
(265
kgf.cm,
19
ft..lbf)
—
—
BODY PANEL REPLACEMENT
BP-85
T = 11.5 N.m
T = 27.0 N.m
T = 19.0 N.m
F22803
11.5
N.m
(117
kgf.cm,
8
ft..lbf)
19.0
N.m
(194
kgf.cm,
14
ft..lbf)
27.0
N.m
(275
kgf.cm,
20
ft..lbf)
BODY PANEL REPLACEMENT
BP-86
FIT STANDARDS
7.5 mm
2.0 mm
3.5 mm
3.7 mm
3.7 mm
6.0 mm
5.4 mm
2.8 mm
6.0 mm
F23343
2.0 mm (0.079 in.)
2.8 mm (0.110 in.)
3.5 mm (0.138 in.)
3.7 mm (0.146 in.)
5.4 mm (0.213 in.)
6.0 mm (0.236 in.)
7.5 mm (0.295 in.)
—
—
BODY PANEL REPLACEMENT
BP-87
[3 Door]
5.0 mm
4.0 mm
4.0 mm
5.6 mm
[5 Door]
5.0 mm
5.0 mm
4.0 mm
4.8 mm
4.0 mm
5.6 mm
5.6 mm
F23335
4.0 mm (0.157 in.)
4.8 mm (0.189 in.)
5.0 mm (0.197 in.)
5.6 mm (0.220 in.)
—
—
PAINT COATING
PC-1
BODY PANEL SEALING AREAS
HINT:
1) Prior to applying body sealer, clean the area with a rag soaked in silicone remover.
2) If weld-through primer was used, first wipe off any excess and than coat with anti-corrosion primer before applying body sealer.
3) Wipe off excess body sealer with a rag soaked in silicone remover.
4) Besure to repair as necessary if the body sealer shows signs of damage such as peeling or cracking.
Flat Finishing
1.
No Flat Finishing
ENGINE COMPARTMENT
F22806
PAINT COATING
PC-2
2.
INSIDE
F22336
PAINT COATING
3.
PC-3
OUTSIDE
F22337
PAINT COATING
PC-4
4.
DOOR PARTS
[3 Door]
F22338
PAINT COATING
PC-5
[5 Door]
F23339
PC-6
PAINT COATING
F22810
PAINT COATING
PC-7
BODY PANEL UNDER COATING AREAS
HINT:
1) First wipe off any dirt, grease or oil with a rag soaked in silicone remover.
2) Cover the surrounding areas with masking paper to avoid coating unnecessary areas. If other areas are accidently coated, wipe off the coating immediately.
3) Apply the first coating of undercoat to all welded areas and panel joints, then apply a second coat over the
entire area.
4) Do not coat parts which become hot such as the tailpipe, and moving parts such as the propeller shaft.
5) Apply under coating to all weld points under the body to ensure corrosion prevention at every location except
the areas below.
6) Be sure to seal the edge of the flange of the member and bracket with undercoating.
7) Be sure to repair the under coating as necessary if there are signs of damage such as cracking or peeling.
8) Apply sealer before applying the under coat for rust prevention.
[LH]
[RH]
F23340
POINT
1
The film thickness of the interior portion of the rear wheel housing should be 1.0 mm (0.04 in.) or more for the
front half and 2.0 mm (0.08 in.) of more for the rear half.
REFERENCE
The under coating should be applied according to the specifications for your country while referring to the
notes above.
PC-8
PAINT COATING
FOAMED MATERIAL APPLICATION AREAS
The sections shown in the figure below are filled with foamed material to provide noise insulation.
Refill with foamed materials after repairing these sections and their surrounding sections.
HINT:
1) Use the service holes located on the reverse side of the body panel to refill foamed materials.
2) Follow manufacturer directions when handling the foamed material.
[5 Door Only]
F23341
PAINT COATING
PC-9
BODY PANEL ANTI-RUST AGENT (WAX) APPLICATION AREAS
HINT:
1) Apply anti-rust agent (wax) around the hinges whenever adjusting the doors and hoods.
2) Even if partially repairing a part, apply anti-rust agent (wax) over the entire application area of the part.
3) Wipe off the anti-rust agent immediately with a rag soaked in silicone remover if it is accidentally applied to
other areas.
F23344
PAINT COATING
PC-10
BODY PANEL ANTI-CHIPPING PAINT APPLICATION AREAS
HINT:
1) Anti-chipping paint should be applied to some areas before the second coat and to other areas after the top
coat.
2) Wipe off the paint immediately with a rag soaked in silicone remover if unrelated areas are accidentally coated.
F23342
PVC
Soft−Chip (Poly Olefine)
—
—
BODY DIMENSIONS
Three-dimensional
distance
Center-to-center
straight-line
distance
DI-1
GENERAL INFORMATION
1.
BASIC DIMENSIONS
(a) There are two types of dimensions in the diagram.
(1) (Three-dimensional distance)
Straight-line distance between the centers of two
measuring points.
Center-to-center horizontal
distance in forward /
rearward direction
Two-dimensional
distance
Vertical distance
to center
Vertical distance
to lower surface
Imaginary Standard Line
(2) (Two-dimensional distance)
Horizontal distance in forward/rearward direction between the centers of two measuring points.
The height from an imaginary standard line.
(b) In cases in which only one dimension is given, left and right
are symmetrical.
(c) The dimensions in the following drawing indicate actual distance. Therefore, please use the dimensions as a reference.
(d) The line that connects the places listed below is the imaginary standard line when measuring the height. (The dimensions are printed in the text.)
Under Surface of
The Rocker Panel
A mm
B mm
C mm
Imaginary Standard Line
SYMBOL
Name
1
The place that was lowered A mm from the under surface of
the rocker panel centered on the front jack up point.
2
The place that was lowered B mm from the under surface of
the rocker panel centered between 1 and 3.
3
The place that was lowered C mm from the under surface of
the rocker panel centered on the rear jack up point.
BODY DIMENSIONS
DI-2
Plate Looseness
Body Looseness
Pointer Looseness
2.
MEASURING
(a) Basically, all measurements are to be done with a tracking
gauge. For portions where it is not possible to use a tracking gauge, a tape measure should be used.
(b) Use only a tracking gauge that has no looseness in the
body, measuring plate, or pointers.
Pointer
Master Gauge
Wrong
Correct
Pointer
HINT:
1) The height of the left and right pointers must be equal.
2) Always calibrate the tracking gauge before measuring
or after adjusting the pointer height.
3) Take care not to drop the tracking gauge or otherwise
shock it.
4) Confirm that the pointers are securely in the holes.
(c) When using a tape measure, avoid twists and bends in the
tape.
BODY DIMENSIONS
DI-3
BODY DIMENSION DRAWINGS
ENGINE COMPARTMENT
(Three-Dimensional Distance)
1,373
(54.06)
745
(29.33)
1,361
(53.58)
690
(27.17)
576
(22.68)
1,261
(49.65)
620
(24.41)
1,131
(44.53)
572
(22.52)
646
(25.43)
1,433
(56.42)
749
(29.49)
1,026
(40.39)
1,126
(44.33)
1,047
(41.22)
680
(26.77)
766
(30.16)
584
(22.99)
944
(37.17)
957
(37.68)
937
(36.89)
262
(10.31)
846
(33.31)
Vehicle Dimensions
Height from Imaginary Standard Line
A-a
A-C
or
a-c
B-C
or
b-c
B-c
or
b-C
B-K
or
b-k
B-k
or
b-K
K-k
A, a
C, c
G, g
1,324
(52.13)
170
(6.69)
209
(8.23)
1,261
(49.65)
564
(22.20)
942
(37.09)
505
(19.88)
810
(31.89)
815
(32.09)
614
(24.17)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
Hole dia.
Symbol
mm (in.)
Name
Hole dia.
A, a
Front fender installation nut
M6 (0.24)
G, g
Headlight bracket standard hole
B, b
Front spring support hole−inner
ø 11 (0.43)
H, h
Crush box installation hole
C, c
Hood hinge installation nut-rear
M8 (0.31)
I, i
Radiator seal installation hole
ø 9 (0.35)
—
J, j
Front fender mounting bracket standard hole
ø 10 (0.39)
Front bumper installation hole
ø 7 (0.28)
D
Cowl panel center mark
E, e
Front side member standard hole
ø 15 (0.59)
K, k
F, f
Front side member standard hole
ø 10 (0.39)
—
—
ø 10 (0.39)
ø 6.3 (0.248)
—
BODY DIMENSIONS
DI-4
BODY OPENING AREAS (Side View)
3-Door
(Three-Dimensional Distance)
1,050
(41.34)
903
(35.55)
663
(26.10)
1,502
(59.13)
982
(38.66)
1,373
(54.06)
894
(35.20)
1,239
(48.78)
1,085
(42.72)
1,266
(49.84)
1,060
(41.73)
1,145
(45.08)
Vehicle Dimensions
E-e
F-f
G-g
H-h
I-i
J-j
K-k
1,147
(45.16)
1,379
(54.29)
1,417
(55.79)
1,417
(55.79)
1,090
(42.91)
1,258
(49.53)
1,395
(54.92)
E-f
or
e-F
E-h
or
e-H
E-j
or
e-J
E-k
or
e-K
F-j
or
f-J
F-k
or
f-K
G-h
or
g-H
H-i
or
h-I
J-k
or
j-K
1,532
(60.31)
1,609
(63.35)
1,372
(54.02)
1,549
(60.98)
1,826
(71.89)
1,745
(68.70)
1,440
(56.69)
1,650
(64.96)
1,429
(56.26)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
mm (in.)
Name
Hole dia.
Symbol
Name
A, a
Roof panel corner
—
G, g
Rocker panel assembly mark
—
B, b
Hood hinge installation nut
M8 (0.31)
H, h
Rocker panel assembly mark
—
C, c
Front door hinge installation nut
M8 (0.31)
I, i
Roof side rail assembly mark
—
D, d
Front door hinge installation nut
M8 (0.31)
J, j
Quarter panel assembly mark
—
E, e
Front body pillar assembly mark
—
K, k
Quarter panel assembly mark
—
F, f
Front body pillar assembly mark
—
—
—
Hole dia.
—
BODY DIMENSIONS
DI-5
BODY OPENING AREAS (Side View: Front)
5-Door
(Three-Dimensional Distance)
1,050
(41.34)
903
(35.55)
522
(20.55)
1,502
(59.13)
982
(38.66)
1,085
(42.72)
1,373
(54.06)
1,062
(41.81)
761
(29.96)
1,147
(45.16)
856
(33.70)
999
(39.33)
Vehicle Dimensions Left Right
E-e
F-f
G-g
H-h
I-i
J-j
K-k
1,147
(45.16)
1,379
(54.29)
1,417
(55.79)
1,417
(55.79)
1,090
(42.91)
1,263
(49.72)
1,391
(54.76)
E-f
or
e-F
E-h
or
e-H
E-j
or
e-J
F-j
or
f-J
F-k
or
f-K
H-i
or
h-I
I-q
or
I-Q
J-k
or
j-K
1,532
(60.31)
1,609
(63.35)
1,312
(51.65)
1,748
(68.82)
1,628
(64.09)
1,650
(64.96)
1,260
(49.61)
1,431
(56.34)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
A, a
Roof panel corner
mm (in.)
Hole dia.
Symbol
—
H, h
Rocker panel assembly mark
Name
Hole dia.
—
B, b
Hood hinge installation nut
M8 (0.31)
I, i
Roof side rail assembly mark
—
C, c
Front door hinge installation nut
M8 (0.31)
J, j
Center body pillar assembly mark
—
D, d
Front door hinge installation nut
M8 (0.31)
K, k
Center body pillar assembly mark
E, e
Front body pillar assembly mark
—
L, l
Rear door hinge installation nut
M8 (0.31)
F, f
Front body pillar assembly mark
—
M, m
Rear door hinge installation nut
M8 (0.31)
G, g
Rocker panel assembly mark
—
Q, q
Roof side rail assembly mark
—
—
BODY DIMENSIONS
DI-6
BODY OPENING AREAS (Side View: Rear)
5-Door
(Three-Dimensional Distance)
723
(28.46)
905
(35.63)
973
1,076 (38.31)
(42.36)
846
(33.31)
815
(32.09)
598
(23.54)
Vehicle Dimensions Left Right
N-n
O-o
P-p
Q-q
R-r
S-s
1,263
(49.72)
1,381
(54.37)
1,417
(55.79)
1,068
(42.05)
1,130
(44.49)
1,405
(55.31)
G-p
or
g-P
N-r
or
n-R
N-s
or
n-S
O-r
or
o-R
O-s
or
o-S
P-q
or
p-Q
R-s
or
r-S
1,717
(67.60)
1,397
(55.00)
1,578
(62.13)
1,584
(62.36)
1,516
(59.69)
1,634
(64.33)
1,451
(57.13)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
Hole dia.
Symbol
mm (in.)
Name
Hole dia.
G, g
Rocker panel assembly mark
—
Q, q
Roof side rail assembly mark
—
N, n
Center body pillar assembly mark
—
R, r
Quarter panel assembly mark
—
O, o
Center body pillar assembly mark
—
S, s
Quarter panel assembly mark
—
P, p
Quarter panel assembly mark
—
—
—
—
BODY DIMENSIONS
DI-7
BODY OPENING AREAS (Rear View)
3-Door
(Three-Dimensional Distance)
1,793
(70.59)
1,020
(40.16)
1,423
(56.02)
1,247
(49.09)
441
(17.36)
1,152
917
(36.10) (45.35) 725
(28.54)
907
(35.71)
1,103
(43.43)
1,333
(52.48)
1,090
(42.91)
678
(26.69)
649
(25.55)
410
(16.14)
787
(30.98)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
A, a
Back door hinge installation hole
B, b
Back door stay installation nut
C, c
Back door opening trough standard hole
D, d
Back door opening trough/Body lower back
panel adjoining point
mm (in.)
Hole dia.
Symbol
Name
ø 10.2 (0.402): RH
ø 10.2 (0.402) 12 (0.47): LH
E, e
Back door lock striker installation nut
M6 (0.24)
F, f
Rear shock absorber installation hole−inner
ø 10 (0.39)
G, g
Roof side rail assembly mark
—
—
—
Hole dia.
M8 (0.31)
ø 18 (0.71)
—
—
BODY DIMENSIONS
DI-8
BODY OPENING AREAS (Rear View)
5-Door
(Three-Dimensional Distance)
1,624
(63.94)
1,020
(40.16)
1,122
(44.17)
441
(17.36)
1,247
(49.09)
1,152
907 (45.35)
(35.71)
725
(28.54)
917
(36.10)
1,333
(52.48)
1,090
(42.91)
649
(25.55) 1,103
678
(26.69)
410
(16.14)
(43.43)
787
(30.98)
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
A, a
Back door hinge installation hole
B, b
Back door stay installation nut
C, c
Back door opening trough standard hole
D, d
Back door opening trough/Body lower back
panel adjoining point
mm (in.)
Hole dia.
Symbol
Name
ø 10.2 (0.402): RH
ø 10.2 (0.402) 12 (0.47): LH
E, e
Back door lock striker installation nut
M6 (0.24)
F, f
Rear shock absorber installation hole−inner
ø 10 (0.39)
G, g
Center body pillar assembly mark
—
—
—
Hole dia.
—
M8 (0.31)
ø 18 (0.71)
—
BODY DIMENSIONS
DI-9
UNDER BODY
(Three-Dimensional Distance)
598
(23.54)
453
(17.83)
RH
536
276
796 (10.87)
(21.10)
(31.34)
844
(33.23) 796
(31.34)
727
759
854
(28.62)
(29.88)
637
(33.62)
(25.08)
1,100
(43.31)
645
768
478
(25.39)
(30.24) (18.82)
991
(39.02)
1,096
(43.15)
1,068
(42.05)
LH
410
(16.14)
1,120
(44.09)
1,060
(41.73)
1,266
(49.84)
920
(36.22)
1,228
(48.35)
1,085
(42.72)
453
(17.83)
415
(16.34)
1,231
(48.46)
1,096
(43.15)
872
(34.33)
967
930
(38.07) (36.61)
957
(37.68)
795
(31.30)
998
(39.29)
1,331
(52.40)
979
(38.54)
462
(18.19)
310
(12.20)
653
(25.71)
Front
A, a
B, b
C, c
152
396
304
(5.98) (15.59) (11.97)
D, d E, e F, f
243 141
54
(9.57) (5.55) (2.13)
G-g
1
2
3
390
(15.35)
100
(3.94)
100
(3.94)
100
(3.94)
G, g H, h
75
51
(2.95) (2.01)
I, i
56
(2.20)
J, j K, k L, l
98 137 276
(3.86) (5.39) (10.87)
M, m
271
(10.67)
N, n
288
(11.34)
Imaginary
Standard
Line
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
A, a
Radiator side support installation nut
Hole dia.
Symbol
M6 (0.24)
H, h
mm (in.)
Name
Hole dia.
Front side member standard hole
ø 18 (0.71)
B, b
Crush box installation hole
ø 6.3 (0.248)
I, i
Front floor pan standard hole
ø 18 (0.71)
C, c
Front side member standard hole
ø 18 (0.71)
J, j
Floor side inner rear member standard hole
ø 18 (0.71)
D, d
Front suspension installation nut
M12 (0.47)
K, k
Trading arm installation outer hole−inner
ø 15 (0.59)
E, e
Front suspension installation nut
M14 (0.55)
L, l
Rear floor sidemember standard hole
ø 18 (0.71)
F, f
Torque box front standard hole
ø 25 (0.98)
M, m
Rear spring plate standard hole
ø 18 (0.71)
G, g
Front floor pan standard hole
ø 18 (0.71)
N, n
Rear floor sidemember standard hole
ø 18 (0.71)
BODY DIMENSIONS
DI-10
UNDER BODY
(Two-Dimensional Distance)
1,887 1,707
(74.29) (67.20)
1,271
(50.04)
925
(36.42)
RH
484
465
(19.06) (18.31)
490
(19.29)
1,149
(45.24)
665
(26.18)
550
(21.65)
614
(24.17)
646
822
(25.43) (32.36)
0
546
(21.50)
530
(20.87)
422
(16.61)
205
(8.07)
479
(18.86)
436
(17.17)
1,781
(70.12)
1,298
(51.10)
195
(7.68)
384
(15.12)
205
(8.07)
614
(24.17)
LH
Wheel Base
0
645
(25.39)
1,080
(42.52)
2,460 (96.85)
718
(28.27)
1
2
3
100
(3.94)
100
(3.94)
100
(3.94)
489
(19.25)
460
(18.11)
1,037
(40.83)
1,345
(52.95)
Front
A, a B, b C, c
E, e D, d F, f G, g
152 396 304
734
243 141 54
(5.98) (15.59) (11.97) (28.90) (9.57) (5.55) (2.13)
H, h I, i
75
51
(2.95) (2.01)
J, j
56
(2.20)
K, k
98
(3.86)
M, m N, n O, o
P, p
276
271
607
288
(10.87) (10.67) (23.90) (11.34)
L, l
137
(5.39)
Imaginary
Standard
Line
HINT: For symbols, capital letters indicate right side of vehicle, small
letters indicate left side of vehicle (seen from rear).
Symbol
Name
A, a
Radiator side support installation nut
B, b
Crush box installation hole
C, c
D, d
E, e
F, f
Hole dia.
Symbol
mm (in.)
Name
Hole dia.
M6 (0.24)
I, i
Front side member standard hole
ø 18 (0.71)
ø 6.3 (0.248)
J, j
Front floor pan standard hole
ø 18 (0.71)
Front side member standard hole
ø 18 (0.71)
K, k
Floor side inner rear member standard hole
ø 18 (0.71)
Front suspension member installation nut
M12 (0.47)
L, l
Trading arm installation outer hole−inner
ø 15 (0.59)
Front spring support plate standard hole−outer
ø 11 (0.43)
M, m
Rear floor sidemember standard hole
ø 18 (0.71)
Front suspension member installation nut
M14 (0.55)
N, n
Rear spring plate standard hole
ø 18 (0.71)
G, g
Torque box front standard hole
ø 25 (0.98)
O, o
Rear shock absorber installation hole
ø 18 (0.71)
H, h
Front floor pan standard hole
ø 18 (0.71)
P, p
Rear floor sidemember standard hole
ø 18 (0.71)
BODY DIMENSIONS
DI-11
REFERENCE VALUE
ENGINE COMPARTMENT
(Three-Dimensional Distance)
1,324
(52.13)
1,361
(53.58)
618
(24.33)
1,025
(40.35)
1,008
(39.69)
590
(23.23)
505
(19.88)
C-c
C-D
or
c-d
1,324
(52.13)
38
(1.50)
HINT: These values are actual measurements made on a vehicle.
Use these reference values.
Symbol
Name
Hole dia.
Symbol
mm (in.)
Name
Hole dia.
A, a
Front bumper cover installation bolt
—
C, c
Headlight installation bolt
—
B, b
Front end of fender
—
D, d
Front fender installation bolt
—
BODY DIMENSIONS
DI-12
UNDER BODY
(Two-Dimensional Distance)
Radiator support installation
4 M10 NUT
11
15
25.0
142.6
2.3
11
15
2.3
1.6
Front spring support
2 11
52
2.8
0.6
51.2
63.6 34.1
Rear shock absorber installation
2.3
2.0
4.9
20.6
5.5
13.6
2.0
mm
FOREWORD
This repair manual has been prepared to provide essential information on body panel repair methods (including cutting and
welding operations, but excluding painting) for the TOYOTA
YARIS.
Applicable models: KSP90 series
NCP90, 91, 92, 93 series
SCP90 series
NLP90 series
This manual consists of body repair methods, exploded diagrams and illustrations of the body components and other information relating to body panel replacement such as handling
precautions, etc. However, it should be noted that the front fenders of, this TOYOTA model are bolted on and require no welding.
When repairing, don’t cut and join areas that are not shown in
this manual. Only work on the specified contents to maintain
body strength.
Body construction will sometimes differ depending on specifications and country of destination. Therefore, please keep in mind
that the information contained herein is based on vehicles for
general destinations.
For the repair procedures and specifications other than collisiondamaged body components of the TOYOTA YARIS refer to the
repair manuals.
If you require the above manuals, please contact your TOYOTA
dealer.
All information contained in this manual is the most up-to-date at
the time of publication. However, specifications and procedures
are subject to change without prior notice.
HOW TO USE THIS MANUAL
Scope of the repair work explanation
This text explains the welding panel replacement instructions from the vehicle’s white body condition. We have abbreviated the explanations of the removal and reinstallation of the equipment parts
up to the white body condition and of the installation, inspection, adjustment and final inspection of
equipment parts after replacing the weld panel.
Section categories
This manual has been divided as shown below.
Section Title
Contents
Examples
INTRODUCTION
Explanation of general body repair.
Views of weld panel replacement instructions.
Cautionary items.
Views of weld panel replacement instructions.
BODY PANEL REPLACEMENT
Instructions for replacing the weld panels
from the white body condition, from which
bolted parts have been removed, with
individual supply parts.
Front side member replacement.
Quarter panel replacement.
BODY DIMENSIONS
Body aligning measurements.
Dimension diagrams.
PAINT COATING
Scope and type of anti-rust treatment, etc.
together with weld panel replacement.
Under coating.
Body sealer.
Contents omitted in this manual.
Make sure to perform the following essential procedures, although they are omitted in this manual.
(1) Jack and lift operations.
(2) Clean and wash removed parts, if necessary.
(3) Visual inspection.
INTRODUCTION
IN-1
GENERAL REPAIR INSTRUCTIONS
1.
WORK PRECAUTIONS
(a) VEHICLE PROTECTION
(1) When welding, protect the painted surfaces, windows,
seats and carpet with heat resistant, fireproof covers.
Glass Cover
Seat Cover
F10001A
(b) SAFETY
(1) Never stand in a direct line with the chain when using a
puller on the body or frame, and be sure to attach a
safety cable.
WRONG
F10002A
(2) Before performing repair work, check for fuel leaks.
If a leak is found, be sure to close the opening completely.
(3) If it is necessary to use a flame in the area of the fuel
tank, first remove the tank and plug the fuel line.
WRONG
F10003A
(c)
F10004A
SAFETY WORK CLOTHES
(1) In addition to the usual mechanic’s wear, cap and
safety shoes, the appropriate gloves, head protector,
glasses, ear plugs, face protector, dust-prevention
mask, etc. should be worn as the situation demands.
Code
Name
A
Dust-Prevention Mask
B
Face Protector
C
Eye Protector
D
Safety Shoes
E
Welder’s Glasses
F
Ear Plugs
G
Head Protector
H
Welder’s Gloves
INTRODUCTION
IN-2
2.
HANDLING PRECAUTIONS OF PLASTIC BODY PARTS
(1) The repair procedure for plastic body parts must conform with the type of plastic material.
(2) Plastic body parts are identified by the codes in the following table.
(3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, painting etc.), consideration must be given to the properties of the plastic.
Code
Material
name
Heat*
resistant
temperature
limit C (F)
Resistance to
alcohol or gasoline
Notes
AAS
Acrylonitrile
Acrylic Styrene
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
ABS
Acrylonitrile
Butadiene Styrene
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
AES
Acrylonitrile
Ethylene Styrene
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
ASA
Acrylonitrile
Styrene
Acrylate
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
CAB
Cellulose
Acetate
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
EPDM
Ethylene
Propylene
100
(212)
Alcohol is harmless.
Gasoline is harmless if applied only for
short time in small amounts.
Most solvents are harmless
but avoid dipping in gasoline,
solvents, etc.
FRP
Fiber
Reinforced
Plastics
180
(356)
Alcohol and gasoline are harmless.
Avoid alkali.
EVA
Ethylene
Acetate
70
(158)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
E / VAC
Ethylene /
Vinyl
Acetate
Copolymer
Resin
70
(158)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid gasoline and organic
or aromatic solvents.
PA
Polyamide
(Nylon)
80
(176)
Alcohol and gasoline are harmless.
Avoid battery acid.
PBT
Polybutylene
Terephthalate
160
(320)
Alcohol and gasoline are harmless.
Most solvents are harmless.
PC
Polycarbonate
120
(248)
Alcohol is harmless.
Avoid gasoline, brake fluid,
wax, wax removers and
organic solvents. Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.
INTRODUCTION
Code
Material
name
Heat*
resistant
temperature
limit C (F)
Resistance to
alcohol or gasoline
IN-3
Notes
PE
Polyethylene
80
(176)
Alcohol and gasoline are harmless.
Most solvents are harmless.
PET
Polyethylene
Terephthalate
75
(167)
Alcohol and gasoline are harmless.
Avoid dipping in water.
PMMA
Polymethyl
Methacrylate
80
(176)
Alcohol is harmless if applied only for
short time in small amounts.
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
Polyoxymethylene
(Polyacetal)
100
(212)
Alcohol and gasoline are harmless.
Most solvents are harmless.
PP
Polypropylene
80
(176)
Alcohol and gasoline are harmless.
Most solvents are harmless.
PPF
Composite
Reinforced
Polypropylene
80
(176)
Alcohol and gasoline are harmless.
Most solvents are harmless.
PPO
Modified
Polyphenylene
Oxide
100
(212)
Alcohol is harmless.
Gasoline is harmless if
applied only for quick wiping
to remove grease.
Polystyrene
60
(140)
Alcohol and gasoline are harmless if
applied only for short time in small
amounts.
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
PUR
Polyurethane
80
(176)
Alcohol is harmless if applied only for very
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
PVC
Polyvinylchloride
(Vinyl)
80
(176)
Alcohol and gasoline are harmless if
applied only for short time in small
amounts (e.g., quick wiping to remove
grease).
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
SAN
Styrene
Acrylonitrile
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
TPO
Thermoplastic
Olefine
80
(176)
Alcohol is harmless.
Gasoline is harmless if applied only for
short time in small amounts.
Most solvents are harmless
but avoid dipping in gasoline,
solvents, etc.
TPU
Thermoplastic
Polyurethane
80
(176)
Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).
Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
TOYOTA
Super
Olefine Polymer
80
(176)
Alcohol and gasoline are harmless.
Most solvents are harmless.
Unsaturated
Polyester
110
(233)
Alcohol and gasoline are harmless.
Avoid alkali.
POM
PS
TSOP
UP
*Temperatures higher than those listed here may result in material deformation during repair.
INTRODUCTION
IN-4
3.
LOCATION OF PLASTIC BODY PARTS
Parts Name
Code
Front Bumper Cover
TSOP
Front Spoiler Cover
TSOP TPO
Radiator Grille
AES
Headlight
PC/PP
Foglight
PBT/ASA
Front Pillar Upper Cover (Hatchback)
AES
Front Pillar Cover (Sedan)
AES
Side Turn Signal Light
PMMA/PC/ABS
Cowl Top Ventilator Louver
TSOP
Outer Rear View Mirror
PA/ABS ASA PP
Door Outside Handle
PA/PC/PBT
Mudguard
PP
Back Door Outside Handle (Hatchback)
PA
Luggage Compartment Door Outside Garnish (Sedan)
ABS
Rear Spoiler (Sedan)
ABS
License Plate Light
PC
Rear Combination Light
PMMA/ABS
Rear Bumper Cover
TSOP
HINT:
Resin material differs depending on model.
/ Made up of 2 or more kinds of materials.
INTRODUCTION
IN-5
HOW TO USE THIS MANUAL
1.
BODY PANEL REPLACEMENT IN THIS MANUAL
BODY PANEL REPLACEMENT
QUARTER PANEL (CUT)
REPLACEMENT
REMOVAL
POINT
1. Remove the [A] at the same time.
PART NAME
[A] Fuel filler opening lid
200 mm (7.87 in.)
REPLACEMENT PART AND METHOD
QUARTER PANEL (CUT)
Replacement method
(ASSY)...Assembly replacement
(CUT)...Major cutting (less than 1/2 of part used)
(CUT-H)...Half cutting (about 1/2 of part used)
(CUT-P)...Partial cutting (most of part used)
Replacement part
REMOVAL CONDITIONS
PART LOCATION
REMOVAL DIAGRAM
Describes in detail the removal of the damaged part involving repair by cutting.
REMOVAL GUIDE
Provides additional information to more efficiently help you perform the removal.
F13890A
INTRODUCTION
IN-6
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
POINT
1. Before temporarily installing the new parts, apply sealer to the wheel arch.
HINT
1) Apply body sealer about 5 mm (0.20 in.) front the flange, avoiding any oozing.
2) Apply sealer evenly, about 3−4 mm (0.12−0.16 in.) in diameter
3) For other sealing points, refer to section PC.
INSTALLATION CONDITIONS
INSTALLATION DIAGRAM
Describes in detail the installation of the new parts involving repair by welding and/or
cutting, but excluding painting.
INSTALLATION GUIDE
Provides additional information to more efficiently help you perform the installation.
SYMBOLS
(See page IN-7)
INSTALLATION OF WELD POINTS
Weld method and panel position symbols (See page IN-9)
PART NAME
F13891A
INTRODUCTION
2.
IN-7
SYMBOLS
The following symbols are used in the welding diagrams in section BP of this manual to indicate cutting areas
and the types of weld required.
SYMBOLS
MEANING
ILLUSTRATION
CUT AND JOIN LOCATION
(Saw Cut)
CUT AND JOIN LOCATION
(Cut Location for
Supply Parts)
CUT LOCATION
CUT WITH DISC
SANDER, ETC.
BRAZE
(Removal)
BRAZE
(Installation)
WELD POINTS
SPOT WELD OR
MIG PLUG WELD
(See page IN-9)
CONTINUOUS
MIG WELD
(BUTT WELD)
CONTINUOUS
MIG WELD
(TACK WELD)
BODY SEALER
F13893A
INTRODUCTION
IN-8
SYMBOLS
—
MEANING
ILLUSTRATION
Assembly Mark
—
—
BODY SEALER
(Flat Finishing)
—
BODY SEALER
(No Flat Finishing)
F13894A
INTRODUCTION
IN-9
3. ILLUSTRATION OF WELD POINT SYMBOLS
EXAMPLE:
REMOVAL
INSTALLATION
Weld points
Weld points
Remove weld point and panel position
SYMBOLS
MEANING
ILLUSTRATION
Remove
Weld
Points
Weld method and panel position
SYMBOLS
MEANING
ILLUSTRATION
Spot Weld
(Outside)
MIG Plug
Weld
(Middle)
(Inside)
HINT: Panel position symbols are as seen from
the working posture.
Spot MIG
Weld
F13892A
INTRODUCTION
IN-10
PROPER AND EFFICIENT WORK
PROCEDURES
1.
REMOVAL
(a) PRE-REMOVAL MEASURING
(1) Before removal or cutting operations, take measurements in accordance with the dimensions diagram. Always use a puller to straighten a damaged body or
frame.
F10007A
(b) CUTTING AREA
(1) Always cut in a straight line and avoid reinforced
areas.
Cutting Okay
Reinforcement
Corners
F10008A
(c)
WRONG
PRECAUTIONS FOR DRILLING OR CUTTING
(1) Check behind any area to be drilled or cut to ensure
that there are no hoses, wires, etc., that may be damaged.
HINT: See “Handling Precautions on Related Components” on page IN-15.
F10009A
(d) REMOVAL OF ADJACENT COMPONENTS
(1) When removing adjacent components, apply protective tape to the surrounding body and your tools to prevent damage.
HINT: See “Handling Precautions on Related Components” on page IN-15.
F10010A
INTRODUCTION
2.
IN-11
PREPARATION FOR INSTALLATION
(a) SPOT WELD POINTS
(1) When welding panels with a combined thickness of
over 3 mm (0.12 in.), use a MIG (Metal Inert Gas)
welder for plug welding.
HINT: Spot welding does not provide sufficient durability for panels with a combined thickness of over 3
mm (0.12 in.).
Less than
3 mm
F10011A
(b) APPLICATION OF WELD-THROUGH PRIMER
(SPOT SEALER)
(1) Remove the paint from the portion of the new parts
and body to be welded, and apply weld-through primer.
F10012A
(c)
MAKING HOLES FOR PLUG WELDING
(1) For areas where a spot welder cannot be used, use a
puncher or drill to make holes for plug welding.
REFERENCE:
mm (in.)
Thickness of welded portion
Puncher
Size of plug hole
1.0 (0.04) under
5 (0.20) ø over
1.0 (0.04) − 1.6 (0.06)
6.5 (0.26) ø over
1.7 (0.07) − 2.3 (0.09)
8 (0.31) ø over
2.4 (0.09) over
10 (0.39) ø over
F10013A
(d) SAFETY PRECAUTIONS FOR ELECTRICAL COMPONENTS
(1) When welding, there is a danger that electrical components will be damaged by the electrical current flowing
through the body.
(2) Before starting work, disconnect the negative terminal
of the battery and ground the welder near the welding
location of the body.
F10014A
20 − 30 mm
Air Saw
Overlap
F10015A
(e) ROUGH CUTTING OF JOINTS
(1) For joint areas, rough cut the new parts, leaving 20 −
30 mm (0.79 − 1.18 in.) of overlap.
INTRODUCTION
IN-12
3.
Body Measurement Diagrams
INSTALLATION
(a) PRE-WELDING MEASUREMENTS
(1) Always take measurements before installing underbody or engine components to ensure correct assembly. After installation, confirm proper fit.
F10016A
(b) WELDING PRECAUTIONS
(1) The number of welding spots should be as follows.
Spot weld: 1.3 X No. of manufacturer’s spots.
Plug weld: More than No. of manufacturer’s plugs.
(2) Plug welding should be done with a MIG (Metal Inert
Gas) welder. Do not gas weld or braze panels at areas
other than specified.
WRONG
F10017A
(c)
CORRECT
POST-WELDING REFINISHING
(1) Always check the welded spots to ensure they are secure.
(2) When smoothing out the weld spots with a disc grinder, be careful not to grind off too much as this will weaken the weld.
WRONG
F10018A
Old
Spot
Locations
New Spot
Locations
(d) SPOT WELD LOCATIONS
(1) Avoid welding over previously welded areas.
F10020A
Tip Cutter
F10019A
(e) SPOT WELDING PRECAUTIONS
(1) The shape of the tip point of the spot welder significantly affects the strength of the weld. Therefore,
maintain the tip point in the proper shape, and allow it
to cool after every five or six spots.
(2) Completely remove the paint from the areas to be spot
welded, including the seams and the surfaces that
come in contact with the welding tip.
(3) Use a sander to remove any burrs that are created
during spot welding.
INTRODUCTION
4.
Sealer Gun
IN-13
ANTI-RUST TREATMENT AFTER INSTALLATION
(BEFORE PAINTING PROCESS)
(a) BODY SEALER APPLICATION
(1) For water-proofing and anti-corrosion measures, always apply the body sealer to the body panel seams
and hems of the doors, hood, etc.
F10021A
(b) UNDERCOAT APPLICATION
(1) To prevent corrosion and protect the body from damage by flying stones, always apply sufficient undercoating to the bottom surface of the under body and
inside of the wheel housings.
F10022A
5.
ANTI-RUST TREATMENT AFTER INSTALLATION
(AFTER PAINTING PROCESS)
(a) ANTI-RUST AGENT (WAX) APPLICATION
(1) To preserve impossible to paint areas from corrosion,
always apply sufficient anti-rust agent (wax) to the inside of the hemming areas of the doors and hood, and
around the hinges, or the welded surfaces inside the
box-shaped cross sections of the side members, body
pillar, etc.
F10023A
INTRODUCTION
IN-14
6.
ANTI-RUST TREATMENT BY PAINTING
REFERENCE:
Painting prevents corrosion and protects the sheet
metal from damage. In this section, anti-chipping paint
only for anti-corrosion purpose is described.
(a) ANTI-CHIPPING PAINT
(1) To prevent corrosion and protect the body from damage by flying stones, etc., apply anti-chipping paint to
the rocker panel, wheel arch areas, balance panel,
etc.
HINT:
Depending on the model or the application area, there
are cases where the application of anti-chipping paint
is necessary before the second coat or after the top
coat.
Apply the anti-chipping paint after
the top coat.
Apply the anti-chipping paint before
the second coat.
Anti-Chipping Paint
Top Coat
Second Coat
Top Coat
Second Coat
Anti-Chipping Paint
Under Coat (ED Primer)
Under Coat (ED Primer)
Steel Metal
Steel Metal
F10024A
INTRODUCTION
IN-15
HANDLING PRECAUTIONS ON RELATED COMPONENTS
1.
BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and
notes given in the brake (32) section of the repair manual for the relevant model when handling brake
system parts.
NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC system.
2.
DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance and
vibration resistance of the vehicle. After installing components in the sections listed in the table below,
perform alignments to ensure correct mounting angles and dimensions. Body repair must be particularly
accurate to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions given in the repair manual for the relevant model during alignment and section DI of this section.
3.
Component to be aligned
Section of repair manual
for relevant model
Front Wheels
Front Suspension (26) section
Rear Wheels
Rear Suspension (27) section
COMPONENTS ADJACENT TO THE BODY PANELS
Various types of component parts are mounted directly on or adjacently to the body panels. Strictly observe the following precautions to prevent damaging these components and the body panels during handling.
Before repairing the body panels, remove their components or apply protective covers over the components.
Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components and the body paint.
Before removing components from the outer surface of the body, attach protective tape to the body to
ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.
Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.
4.
ECU (ELECTRONIC CONTROL UNIT)
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.
Before starting electric welding operations, disconnect the negative (−) terminal cable from the battery.
When the negative (−) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be canceled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seats and outside rear view mirrors, which are
all equipped with a memory function, it is not possible to make a record of the memory contents.
So when the operation is finished, it will be necessary to explain this fact to the customer, and request
the customer to adjust the features and reset the memory.
Do not expose the ECUs to ambient temperatures above 80C (176F).
NOTICE: If it is possible the ambient temperature may reach 80C (176F) or more, remove the ECUs
from the vehicle before starting work.
Be careful not to drop the ECUs and not to apply physical shocks to them.
IN-16
INTRODUCTION
PRECAUTIONS FOR REPAIRING BODY
STRUCTURE PANELS
1.
HEAT REPAIR FOR BODY STRUCTURE
PANELS
Toyota prohibits the use of the heat repair method on body
structure panels when repairing a vehicle damaged in a collision.
Panels that have high strength and rigidity, as well as a long
life span for the automobile body are in high demand.
At Toyota, in order to fulfill these requirement, we use high
tensile strength steel sheets and rust preventive steel
sheets on the body. High tensile steel sheets are made with
alloy additives and a special heat treatment in order to improve the strength.
To prevent the occurrence of rust for a long period of time,
the surface of the steel is coated with a zinc alloy.
If body structure parts are heat repaired with an acetylene
torch or other heating source, the crystalline organization of
the steel sheet will change and the strength of the steel
sheet will be reduced. The ability of the body to resist rust is
significantly lowered as well since the rust resistant zinc
coating is destroyed by heat and the steel sheet surface is
oxidized.
2.
STRUCTURE PANEL KINKS
A sharp deformation angle on a panel that cannot be returned to its original shape by pulling or hammering is
called a kink.
Structural parts are designed to perform in their original
shape. If parts are deformed in an accident, or if the deformed parts are repaired and reused, the parts may be unable to perform as intended.
It is necessary to replace the part where the kink has occurred.
INTRODUCTION
3.
IN-17
IMPACT BEAM REPAIR
The impact beam and bracket are necessary and important
parts that help reduce the probability of injury to passengers in side collisions.
For impact beams, we use special high tensile strength
steel.
The high tensile strength steel maintains its special crystalline organization by heat treatment or alloy additives.
Structural parts are designed to perform in their original
shape. If parts are deformed in an accident, or if the deformed parts are repaired and reused, the parts may be unable to perform as intended.
If the impact beam or bracket is damaged, replace the door
assembly with the damaged beam.
Also, the bumper reinforcement is a necessary and important part that helps reduce the probability of injury to passengers in front collisions, and for the same reasons explained above, should be replaced if damaged.
IN-18
INTRODUCTION
ABBREVIATIONS USED IN THIS MANUAL
For convenience, the following abbreviations are used in this
manual.
ABS
Antilock Brake System
A/C
Air Conditioner
assy
assembly
ECT
Electronic Controlled Transmission
ECU
Electronic Control Unit
e.g.
Exempli Gratia (for Example)
Ex.
Except
FWD
Front Wheel Drive Vehicles
2WD
Two Wheel Drive Vehicles
4WD
Four Wheel Drive Vehicles
in.
inch
LH
Left-hand
LHD
Left-hand Drive
MIG
Metal Inert Gas
M/Y
Model Year
PPS
Progressive Power Steering
RH
Right-hand
RHD
Right-hand Drive
SRS
Supplemental Restraint System
SSM
Special Service Materials
w/
with
w/o
without
BODY PANEL REPLACEMENT
BP-1
RADIATOR SUPPORT (ASSY)
REPLACEMENT
F22816A
REMOVAL
F22816
POINT
1
*1: Bolt
BP-2
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F22817
POINT
1
Inspect the fitting of the headlight, front fender, hood and other related parts, before welding as this affects the
appearance of the finish.
2
*1: Bolt
BODY PANEL REPLACEMENT
BP-3
[Hatchback]
1,324 mm
530 mm
944 mm
[Sedan]
1,327 mm
380 mm
950 mm
F22818-1
POINT
1
Measure the dimensions before installing the headlight.
2
These values are reference values.
380 mm (14.96 in.)
1,324 mm (52.13 in.)
530 mm (20.87 in.)
1,327 mm (52.24 in.)
944 mm (37.17 in.)
950 mm (37.40 in.)
BODY PANEL REPLACEMENT
BP-10
FRONT SIDEMEMBER REINFORCEMENT
(CUT-P)
REPLACEMENT
With the radiator support removed.
F22825A
REMOVAL
[LH]
140 mm
65 mm
F23301
POINT
1
Remove [A] at the same time.
PART NAME
[A] Front Sidemember Outer Plate
65 mm (2.56 in.)
140 mm (5.51 in.)
BODY PANEL REPLACEMENT
BP-11
[RH]
70 mm
140 mm
F23302
POINT
1
Remove [B] before conducting this work.
2
Remove [A] at the same time.
PART NAME
[B] Engine Front Mounting Bracket
[A] Front Sidemember Outer Plate
70 mm (2.76 in.)
140 mm (5.51 in.)
BODY PANEL REPLACEMENT
BP-12
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
[LH]
F23303
PART NAME
[A] Front Sidemember Outer Plate
BODY PANEL REPLACEMENT
BP-13
[RH]
F23304
POINT
1
Remove the [B] from the new parts of the front sidemember reinforcement.
2
After installing the new parts, install [B].
PART NAME
[A] Front Sidemember Outer Plate
[B]
Engine Front Mounting Bracket
BP-4
BODY PANEL REPLACEMENT
FRONT FENDER MOUNTING BRACKET
(ASSY)
REPLACEMENT
F22819A
REMOVAL
F22819
BODY PANEL REPLACEMENT
BP-5
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F22820
POINT
1
Inspect the fitting of the front fender and other related parts before welding as this affects the appearance of the
finish.
BODY PANEL REPLACEMENT
BP-6
FRONT FENDER APRON (ASSY)
REPLACEMENT
With the cowl top side panel removed.
F22821A
REMOVAL
[RH]
[LH]
F22821
BODY PANEL REPLACEMENT
BP-7
F22822
BODY PANEL REPLACEMENT
BP-8
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
[RH]
[LH]
F22823
POINT
1
Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front
wheel alignment.
2
Inspect the fitting of the front fender, hood and other related parts before welding as this affects the appearance
of the finish.
BODY PANEL REPLACEMENT
BP-9
F22824
BP-14
BODY PANEL REPLACEMENT
FRONT SIDEMEMBER REINFORCEMENT
(ASSY)
REPLACEMENT
With the radiator support and front fender apron removed.
F22829A
REMOVAL
F22829
POINT
1
Remove [A] at the same time.
PART NAME
[A] Front Sidemember Outer Plate
BODY PANEL REPLACEMENT
BP-15
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F22830
POINT
1
Make sure to attach correctly in accordance with the body dimension diagram as this part affects the front
wheel alignment.
BODY PANEL REPLACEMENT
BP-16
[LH]
[RH]
F22831
PART NAME
[A] Front Sidemember Outer Plate
BODY PANEL REPLACEMENT
BP-17
COWL TOP SIDE PANEL (ASSY): Hatchback
REPLACEMENT
F22832A
REMOVAL
F22832
BP-18
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
(20 mm)
(25 mm)
(30 mm)
(15 mm)
F22833
15 mm (0.59 in.)
20 mm (0.79 in.)
25 mm (0.98 in.)
30 mm (1.18 in.)
BODY PANEL REPLACEMENT
BP-19
COWL TOP SIDE PANEL (ASSY): Sedan
REPLACEMENT
F24821A
REMOVAL
F24821-1
BP-20
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
(20 mm)
(25 mm)
(30 mm)
(15 mm)
F24821-2
15 mm (0.59 in.)
20 mm (0.79 in.)
25 mm (0.98 in.)
30 mm (1.18 in.)
BODY PANEL REPLACEMENT
BP-21
COWL TOP SIDE UPPER PANEL (ASSY):
Hatchback
REPLACEMENT
With the cowl top side panel removed.
F22834A
REMOVAL
F22834
BP-22
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
(25 mm)
(25 mm)
F22835
POINT
1
Inspect the fitting of the hood and related parts before welding as this affects the appearance of the finish.
25 mm (0.98 in.)
BODY PANEL REPLACEMENT
BP-23
COWL TOP SIDE UPPER PANEL (ASSY):
Sedan
REPLACEMENT
With the cowl top side panel removed.
F24822A
REMOVAL
F24822-1
BP-24
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
(23 mm)
F24822-2
POINT
1
Inspect the fitting of the hood and related parts before welding as this affects the appearance of the finish.
23 mm (0.91 in.)
BODY PANEL REPLACEMENT
BP-34
CENTER BODY PILLAR (CUT):
Hatchback 5 Door
REPLACEMENT
F22840A
REMOVAL
50 mm
30 mm
30 mm
50 mm
50 mm
F22840
30 mm (1.18 in.)
50 mm (1.97 in.)
BODY PANEL REPLACEMENT
BP-35
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
80 mm
45 mm
(10 mm 7)
F22841
POINT
1
Before temporarily installing the new parts, weld [A], [B] and [C] with standard welding number.
PART NAME
[B] Center Body Pillar Reinforcement
[A] Rocker Outer Reinforce
10 mm (0.39 in.)
45 mm (1.77 in.)
80 mm (3.15 in.)
[C]
Center Body Inner Pillar
BODY PANEL REPLACEMENT
BP-36
(10 mm 4)
F22842
POINT
1
Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appearance of the finish.
2
After welding [A], [B] and [C] to the vehicle, install [D].
PART NAME
[A] Rocker Outer Reinforce
[C] Center Body Inner Pillar
10 mm (0.39 in.)
[B]
[D]
Center Body Pillar Reinforcement
Center Body Outer Pillar
BODY PANEL REPLACEMENT
BP-25
FRONT BODY PILLAR (CUT): Hatchback
REPLACEMENT
With the cowl top side upper panel removed.
F22836A
REMOVAL
100 mm
80 mm
160 mm
70 mm
F22836
POINT
1
*1: This part of the outer panel is reused because the rocker panel section is cut off at a position behind the
service part cut position of the outer panel.
70 mm (2.76 in.)
80 mm (3.15 in.)
100 mm (3.94 in.)
160 mm (6.30 in.)
BP-26
BODY PANEL REPLACEMENT
F22837
BODY PANEL REPLACEMENT
BP-27
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
230 mm
(10 mm 3)
(15 mm 3)
F22838
POINT
1
Before temporarily installing the new parts, weld [A], [B], [C] and [D] with standard welding number.
PART NAME
[B] Front Body Pillar Lower Reinforce
[A] Rocker Outer Reinforce
[D] Front Body Outer Pillar
[C] Front Body Inner Pillar
10 mm (0.39 in.)
15 mm (0.59 in.)
230 mm (9.06 in.)
BP-28
BODY PANEL REPLACEMENT
(10 mm)
(15 mm 2)
F22839
POINT
1
Inspect the fitting of the front fender, front door, windshield glass and other related parts before welding as this
affects the appearance of the finish.
10 mm (0.39 in.)
15 mm (0.59 in.)
BODY PANEL REPLACEMENT
BP-29
FRONT BODY PILLAR (CUT): Sedan
REPLACEMENT
With the cowl top side upper panel removed.
F24823A
REMOVAL
140 mm
160 mm
40 mm
F24823-1
POINT
1
After removing [A], remove the front body pillar.
2
*1: This part of the outer panel is reused because the rocker panel section is cut off at a position behind the
service part cut position of the outer panel.
PART NAME
[A] Front Panel No.1 Bracket
40 mm (1.57 in.)
140 mm (5.51 in.)
160 mm (6.30 in.)
BP-30
BODY PANEL REPLACEMENT
F24824
BODY PANEL REPLACEMENT
BP-31
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
200 mm
(10 mm3)
(15 mm2)
(15 mm)
F24825-1
POINT
1
Before temporarily installing the new parts, weld [B], [C], [D] and [E] with standard welding number.
PART NAME
[B] Rocker Outer Reinforce
[D] Front Body Inner Pillar
10 mm (0.39 in.)
[C]
[E]
Front Body Pillar Lower Reinforce
Front Body Upper Outer Pillar
15 mm (0.59 in.)
200 mm (7.87 in.)
BODY PANEL REPLACEMENT
BP-32
(15 mm)
(15 mm)
(10 mm)
F24826
10 mm (0.39 in.)
15 mm (0.59 in.)
BODY PANEL REPLACEMENT
BP-33
F24827-1
POINT
1
Inspect the fitting of the front fender, front door, window shield glass and other related parts before welding as
this affects the appearance of the finish.
2
After installing the new parts, install [A]
PART NAME
[A] Front Panel No.1 Bracket
BODY PANEL REPLACEMENT
BP-43
FRONT DOOR OUTER PANEL (CUT):
Hatchback 5 Door
REPLACEMENT
F23307A
REMOVAL
Hemming Location
Disc Sander
F23307
POINT
1
After grinding off the hemming location, remove the outer panel.
BP-44
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
10 mm
Do not close
the drain hole.
Cloth Tape
30
Hemming Tool
F23308
POINT
1
Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection
beam and backside of the new parts.
HINT:
1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer
panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact.
2
Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool.
HINT:
1) Perform hemming in three steps, being careful not to warp the panel.
2) If a hemming tool cannot be used, hem with a hammer and dolly.
BODY PANEL REPLACEMENT
BP-37
CENTER BODY PILLAR (CUT): Sedan
REPLACEMENT
F24828A
REMOVAL
40 mm
30 mm
70 mm
90 mm
F24828-1
30 mm (1.18 in.)
40 mm (1.57 in.)
70 mm (2.76 in.)
90 mm (3.54 in.)
BP-38
BODY PANEL REPLACEMENT
15 mm
130 mm
F24829
POINT
1
*1: Take care not to damage the internal reinforcement.
15 mm (0.59 in.)
130 mm (5.12 in.)
BODY PANEL REPLACEMENT
BP-39
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
110 mm
50 mm
(10 mm7)
15 mm
130 mm
F24830-1
POINT
1
Before temporarily installing the new parts, weld [A], [B] and [C] with standard welding number.
PART NAME
[A] Rocker Outer Reinforce
[C] Center Body Inner Pillar
10 mm (0.39 in.)
[B]
15 mm (0.59 in.)
Center Body Pillar Reinforcement
50 mm (1.97 in.)
110 mm (4.33 in.)
130 mm (5.12 in.)
BODY PANEL REPLACEMENT
BP-40
(
(10 mm)
10 mm2)
(10 mm)
F24831-1
POINT
1
Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appearance of the finish.
2
After welding [A], [B] and [C] to the vehicle, install [D].
PART NAME
[A] Rocker Outer Reinforce
[C] Center Body Inner Pillar
10 mm (0.39 in.)
[B]
[D]
Center Body Pillar Reinforcement
Rocker Outer Panel
BODY PANEL REPLACEMENT
BP-45
FRONT DOOR OUTER PANEL (CUT): Sedan
Ex. U.S.A., CANADA
REPLACEMENT
F24875A
REMOVAL
Hemming Location
Disc Sander
F24875
POINT
1
Afer grinding off the hemming location, remove the outer panel.
BP-46
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
10 mm
Do not close the
drain hole.
Cloth Tape
30
Hemming Tool
F24876
POINT
1
Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection
beam and backside of the new parts.
HINT:
1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer
panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact.
2
Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool.
HINT:
1) Perform hemming in three steps, being careful not to warp the panel.
2) If a hemming tool cannot be used, hem with a hammer and dolly.
BODY PANEL REPLACEMENT
BP-41
FRONT DOOR OUTER PANEL (CUT):
Hatchback 3 Door
REPLACEMENT
F23305A
REMOVAL
Hemming Location
Disc Sander
F23305
POINT
1
After grinding off the hemming location, remove the outer panel.
BP-42
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
10 mm
Do not close
the drain hole.
Cloth Tape
30
Hemming Tool
F23306
POINT
1
Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection
beam and backside of the new parts.
HINT:
1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer
panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact.
2
Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool.
HINT:
1) Perform hemming in three steps, being careful not to warp the panel.
2) If a hemming tool cannot be used, hem with a hammer and dolly.
BODY PANEL REPLACEMENT
BP-47
FRONT DOOR OUTER PANEL (CUT): Sedan
U.S.A., CANADA
REPLACEMENT
F24875A
REMOVAL
Hemming Location
Disc Sander
F24877
POINT
1
After grinding off the hemming location, remove the outer panel.
BP-48
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
10 mm
Do not close the
drain hole.
Cloth Tape
30
Hemming Tool
F24878
POINT
1
Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection
beam and backside of the new parts.
HINT:
1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer
panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact.
2
Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool.
HINT:
1) Perform hemming in three steps, being careful not to warp the panel.
2) If a hemming tool cannot be used, hem with a hammer and dolly.
BODY PANEL REPLACEMENT
BP-49
REAR DOOR OUTER PANEL (CUT):
Hatchback 5 Door
REPLACEMENT
F23309A
REMOVAL
Hemming Location
Disc Sander
F23309
POINT
1
After grinding off the hemming location, remove the outer panel.
BP-50
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
10 mm
Do not close the
drain hole.
Cloth Tape
30
Hemming Tool
F23310
POINT
1
Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection
beam and backside of the new parts.
HINT:
1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer
panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact.
2
Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool.
HINT:
1) Perform hemming in three steps, being careful not to warp the panel.
2) If a hemming tool cannot be used, hem with a hammer and dolly.
BODY PANEL REPLACEMENT
BP-51
REAR DOOR OUTER PANEL (CUT): Sedan
Ex. U.S.A., CANADA
REPLACEMENT
F24879A
REMOVAL
Hemming Location
Disc Sander
F24879
POINT
1
After grinding off the hemming location, remove the outer panel.
BP-52
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
10 mm
Do not close the
drain hole.
Cloth Tape
30
Hemming Tool
F24880
POINT
1
Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection
beam and backside of the new parts.
HINT:
1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer
panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact.
2
Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool.
HINT:
1) Perform hemming in three steps, being careful not to warp the panel.
2) If a hemming tool cannot be used, hem with a hammer and dolly.
BODY PANEL REPLACEMENT
BP-53
REAR DOOR OUTER PANEL (CUT): Sedan
U.S.A., CANADA
REPLACEMENT
F24879A
REMOVAL
Hemming Location
Disc Sander
F24881
POINT
1
After grinding off the hemming location, remove the outer panel.
BP-54
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
10 mm
Do not close the
drain hole.
Cloth Tape
30
Hemming Tool
F24882
POINT
1
Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection
beam and backside of the new parts.
HINT:
1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer
panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact.
2
Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool.
HINT:
1) Perform hemming in three steps, being careful not to warp the panel.
2) If a hemming tool cannot be used, hem with a hammer and dolly.
BODY PANEL REPLACEMENT
BP-55
ROCKER OUTER PANEL (CUT-H):
Hatchback 5 Door
REPLACEMENT
F22843A
REMOVAL
380 mm
F22843
380 mm (14.96 in.)
BP-56
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F22844
POINT
1
Inspect the fitting of the front door and other related parts before welding as this affects the appearance of the
finish.
BODY PANEL REPLACEMENT
BP-61
ROCKER OUTER PANEL (CUT):
Hatchback 5 Door
REPLACEMENT
F22845A
REMOVAL
100 mm
F22845
100 mm (3.94 in.)
BP-62
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F22846
POINT
1
Inspect the fitting of the front door, rear door and other related parts before welding as this affects the appearance of the finish.
BODY PANEL REPLACEMENT
BP-57
ROCKER OUTER PANEL (CUT-H): Sedan
REPLACEMENT
F24832A
REMOVAL
420 mm
F24832-1
420 mm (16.54 in.)
BP-58
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F24832-2
POINT
1
Inspect the fitting of the front door and other related parts before welding as this affects the appearance of the
finish.
BODY PANEL REPLACEMENT
BP-59
ROCKER OUTER PANEL (CUT):
Hatchback 3 Door
REPLACEMENT
F23311A
REMOVAL
F23311
BP-60
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F23312
POINT
1
Inspect the fitting of the front door and other related parts before welding as this affects the appearance of the
finish.
BODY PANEL REPLACEMENT
BP-69
QUARTER PANEL (CUT): Hatchback 3 Door
REPLACEMENT
F23313A
REMOVAL
205 mm
645 mm
F23313
POINT
1
*1: The hatched area indicates the adhesive application area.
PART NAME
[A] Quarter Wheel Housing Outer Panel
205 mm (8.07 in.)
645 mm (25.39 in.)
BP-70
BODY PANEL REPLACEMENT
F23314
BODY PANEL REPLACEMENT
BP-71
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
1.0 mm
F23315
POINT
1
*1: The hatched area indicates the adhesive application area.
PART NAME
[A] Quarter Wheel Housing Outer Panel
1.0 mm (0.04 in.)
[B]
Fuel Filler Opening Lid
[C]
Rivet
BP-72
BODY PANEL REPLACEMENT
F23316
POINT
1
Inspect the front door, back door, rear combination light and other related parts before welding as this affects
the appearance of the finish.
BODY PANEL REPLACEMENT
BP-63
ROCKER OUTER PANEL (CUT): Sedan
REPLACEMENT
F24833A
REMOVAL
245 mm
F24833-1
245 mm (9.65 in.)
BP-64
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F24833-2
POINT
1
Inspect the fitting of the front door, rear door and other related parts before welding as this affects the
appearance of the finish.
BODY PANEL REPLACEMENT
BP-82
QUARTER WHEEL HOUSING OUTER PANEL
(ASSY): Hatchback
REPLACEMENT
With the quarter panel removed.
F22851A
REMOVAL
[LH]
3 Door :
5 Door :
3 Door :
5 Door :
F23321
POINT
1
After removing [A], remove the quarter wheel housing outer panel.
PART NAME
[A] Rocker Outer Reinforce
BODY PANEL REPLACEMENT
BP-83
[LH]
40 mm
F22852
POINT
1
After removing [B], remove the quarter wheel housing outer panel.
PART NAME
[B] Roof Side Outer Panel
40 mm (1.57 in.)
BP-84
BODY PANEL REPLACEMENT
[RH]
3 Door :
5 Door :
3 Door :
5 Door :
F23322
POINT
1
After removing [A], remove the quarter wheel housing outer panel.
PART NAME
[A] Rocker Outer Reinforce
BODY PANEL REPLACEMENT
BP-85
[RH]
30 mm
F22854
POINT
1
After removing [B], remove the quarter wheel housing outer panel.
PART NAME
[B] Roof Side Outer Panel
30 mm (1.18 in.)
BODY PANEL REPLACEMENT
BP-86
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
[LH]
F22856
POINT
1
After installing the new parts, install [B].
PART NAME
[B] Roof Side Outer Panel
BODY PANEL REPLACEMENT
BP-87
[LH]
3 Door :
5 Door :
3 Door :
5 Door :
F23323
POINT
1
After installing the new parts, install [A].
PART NAME
[A] Rocker Outer Reinforce
BODY PANEL REPLACEMENT
BP-88
[RH]
F22858
POINT
1
After installing the new parts, install [B].
PART NAME
[B] Roof Side Outer Panel
BODY PANEL REPLACEMENT
BP-89
[RH]
3 Door :
5 Door :
3 Door :
5 Door :
F23324
POINT
1
After installing the new parts, install [A].
PART NAME
[A] Rocker Outer Reinforce
BODY PANEL REPLACEMENT
BP-73
QUARTER PANEL (CUT): Hatchback 5 Door
REPLACEMENT
F22847A
REMOVAL
F23317
POINT
1
*1: The hatched area indicates the adhesive application area.
PART NAME
[A] Quarter Wheel Housing Outer Panel
BP-74
BODY PANEL REPLACEMENT
150 mm
F23318
150 mm (5.91in.)
BODY PANEL REPLACEMENT
BP-75
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
1.0 mm
F23319
POINT
1
*1: The hatched area indicates the adhesive application area.
PART NAME
[A] Quarter Wheel Housing Outer Panel
1.0 mm (0.04 in.)
[B]
Fuel Filler Opening Lid
[C]
Rivet
BP-76
BODY PANEL REPLACEMENT
F23320
POINT
1
Inspect the front door, back door, rear combination light and other related parts before welding as this affects
the appearance of the finish.
BODY PANEL REPLACEMENT
BP-65
Adhesive Application Area Work
Procedure
NOTE
This vehicle has areas on the Quarter Panel and Quarter
Wheel Housing Outer Panel that are joined together only
with adhesive. It is necessary to conduct the correct repair
procedures for high durability so make sure to follow the
instructions below for the adhesive application areas.
Type of adhesive used: 3M8115 Auto Mix Panel Bond
1.
Adhesive Application Area
Cut and Join
Location
Removal of the Quarter Panel
(A) Remove the body sealer from the Quarter Panel and cut at
the cut and join location. Remove the spot welded portions.
(B) After rough cutting the Wheel Arch portion, heat the adhesive applied area and remove the panel. {Heat the Wheel
Arch portion of the Quarter Panel at 110 to 140C (230 to
284F) with a dryer or gas burner and remove the Quarter
Panel.}
Spot Weld
Cut and Join Location
010L23a
2.
010L06
Removal of the previous adhesive coating
(A) Heat at 110 to 140C (230 to 284F) with a dryer or gas
burner.
(B) Scrape away the adhesive with a scraper, and scuff while
sanding with a disc grinder or a belt sander.
NOTE
Make sure to use either a disc grinder or belt sander to
sand coarsely and deeply to improve adhesiveness.
Scuff at a width of approximately 10 mm (0.39 in.) over
the previous adhesive coating.
3.
Treatment of the spot welded portions on
the body
(A) After the adhesive has been removed from the body, remove the paint from the underside of the spot welded points
blow air and degrease.
(B) Apply spot sealer at the joined portion between panels.
approx.10 mm
After sanding
010L07a
BODY PANEL REPLACEMENT
BP-66
4.
Attachment of the New Quarter Panel
(A) Temporarily attach the new panel and check the fitting
condition, the cut and join locations, the welded areas, and
the adhesive applied area.
NOTE
Check the adhesive applied condition to ensure adhesive strength.
Conduct hammering to fix the non-adhered portions.
Cross-Sectional view
Adhesive
1 mm gap
010L10a
5.
Application Area
Scuffed Area
10 mm
28 mm
010L11a
Adhesive Application to New Quarter Panel
(A) Scuff with #60-120 grit sandpaper at the adhesive application area.
POINT
Sand deeply into the ED coat.
(B) Blow air around the scuffed portion and then degrease.
(C) Apply adhesive.
POINT
Apply adhesive at a width of approximately 10 mm (0.39 in.)
at a location 28 mm (1.10 in.) from the panel flange edge.
Spread the adhesive flatly within the scuffed area {approximately 10 mm (0.39 in.) in width} to remove trapped air.
010L12
Approx. 3 mm
3 mm
Adhesive
010L12-1a
010L13
BODY PANEL REPLACEMENT
6.
010L15
BP-67
Application of Adhesive to the Body
(A) Degrease the adhesive aplication area.
(B) Apply adhesive.
Refer to the diagram of step 5 for the application amount.
The application location is 7.5 mm (0.295 in.) from the
flange edge.
(C) Flatten out the applied adhesive with a spatula until it is at
an even level.
Apply adhesive at exposed metal plate portions to prevent corrosion.
It is not necessary to flatten out adhesive after it has
been reapplied.
7.5 mm
Flange Edge
010L16
010L17a
7.
Attachment of the new Quarter Panel
(A) Set the new panel in the position for temporary attachment.
(Be careful of where you hold the panel so as not to touch
the adhesive applied surfaces.)
(B) Secure in a vice grip or equivalent and check the fitting
condition.
(C) Press on the entire surface so that the adhesive between
the Quarter Panel and Quarter Wheel Housing Outer panel
becomes an even thickness.
NOTE
Be careful that adhesive that spills over does not contact
the Brake Drum.
(D) Tack weld at the cut and join welded portion.
(E) Tack weld by spot welding at one point on both ends of the
adhesive applied portions.
(F) Conduct actual welding using procedures in the BP section
of this manual.
Tack Weld
010L20a
BODY PANEL REPLACEMENT
BP-68
8.
Infrared
Ray
Hearter
010L22a
Drying
(A) Clean away adhesive that has spilled over with a degreaser
or equivalent.
(B) After all welding works have been completed, dry the adhesive with a heater.
Hardening Time
Forced drying
60C (140F) at 90 minutes.
Natural drying
24C (75F) (room temperature) for 24 hours.
9.
Other work
(A) After applying Primer Surfacer to the underside of the
Wheel Arch of the Quarter Panel, apply body sealer to the
locations indicated in the body repair manual.
Adhesive
Body Sealer
010L21a
BP-90
BODY PANEL REPLACEMENT
QUARTER WHEEL HOUSING OUTER PANEL
(ASSY): Sedan
REPLACEMENT
With the quarter panel removed.
F24839A
REMOVAL
[LH]
F24839-1
POINT
1
After removing [A], remove the quarter wheel housing outer panel.
PART NAME
[A] Rocker Outer Reinforce
BODY PANEL REPLACEMENT
BP-91
[LH]
F24840-1
POINT
1
After removing [B], remove the quarter wheel housing outer panel.
PART NAME
[B] Roof Side Outer Panel
BP-92
BODY PANEL REPLACEMENT
[RH]
F24841-1
POINT
1
After removing [A], remove the quarter wheel housing outer panel.
PART NAME
[A] Rocker Outer Reinforce
BODY PANEL REPLACEMENT
BP-93
[RH]
F24842-1
POINT
1
After removing [B], remove the quarter wheel housing outer panel.
PART NAME
[B] Roof Side Outer Panel
BP-94
BODY PANEL REPLACEMENT
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
[LH]
F24840-2
POINT
1
After installing the new parts, install [B].
PART NAME
[B] Roof Side Outer Panel
BODY PANEL REPLACEMENT
BP-95
[LH]
F24839-2
POINT
1
After installing the new parts,install [A].
PART NAME
[A] Rocker Outer Reinforce
BP-96
BODY PANEL REPLACEMENT
[RH]
F24842-2
POINT
1
After installing the new parts, install [B].
PART NAME
[B] Roof Side Outer Panel
BODY PANEL REPLACEMENT
BP-97
[RH]
F24841-2
POINT
1
After installing the new parts, install [A].
PART NAME
[A] Rocker Outer Reinforce
BODY PANEL REPLACEMENT
BP-77
QUARTER PANEL (CUT): Sedan
REPLACEMENT
F24834A
REMOVAL
130 mm
150 mm
F24834-1
POINT
1
*1: in illustration above indicates where the adhesive is.
2
Roughly cut open the wheel arch of the panel so that the adhesive can be reached. Cut through the adhesive
with a cut chisel to remove the panel.
HINT:
1) If the cut chisel cannot reach the adhesive, heat the adhesive with a heat gun, oxygen-acetylene burner.
When heating, do not deform the quarter housing outer panel.
130 mm (5.12 in.)
150 mm (5.91 in.)
BP-78
BODY PANEL REPLACEMENT
F24835
BODY PANEL REPLACEMENT
BP-79
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
3 mm
Spot Tip
5 mm
F24836-1
POINT
1
Inspect the fitting of the rear door, luggage compartment door, rear combination light and other related parts
before welding as this affects the appearance of the finish.
2
Apply adhesive (3MTM AutomixTM Panel Bonding Adhesive #8115) to the area indicated by *1 in illustration.
HINT:
1) Apply enough adhesive for the panels to sick to each other.
3
Perform spot-welding on the flange indicated by *2 in the illustration. Modify/ cut the spot tip as shown in the
illustration (*3) so that it can fit into the narrow flange.
3 mm (0.12 in.)
5 mm (0.20 in.)
BODY PANEL REPLACEMENT
BP-80
5 mm
F24837-1
POINT
1
Before temporarily installing the new parts, apply body sealer to the wheel arch.
HINT:
1) Apply body sealer evenly about 5 mm (0.20 in.) form the flange, avoiding any oozing.
2) Apply sealer evenly, about 3 − 4 mm (0.12 − 0.16 in.) in diameter.
5 mm (0.20 in.)
BODY PANEL REPLACEMENT
BP-81
(13 mm)
F24838-1
PART NAME
[A] Fuel Filler Opening Lid
13 mm (0.51 in.)
[B]
Rivets
BP-98
BODY PANEL REPLACEMENT
LOWER BACK UPPER GUSSET (ASSY):
Hatchback
REPLACEMENT
F22859A
REMOVAL
F22859
BODY PANEL REPLACEMENT
BP-99
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
F22860
BP-100
BODY PANEL REPLACEMENT
LOWER BACK UPPER QUSSET (ASSY):
Sedan
REPLACEMENT
F24843A
REMOVAL
F24843-1
BODY PANEL REPLACEMENT
BP-101
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F24843-2
BP-102
BODY PANEL REPLACEMENT
BODY LOWER BACK PANEL (ASSY):
Hatchback
REPLACEMENT
F22861A
REMOVAL
F23325
BODY PANEL REPLACEMENT
BP-103
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F23326
POINT
1
Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects
the appearance of the finish.
BP-104
BODY PANEL REPLACEMENT
BODY LOWER BACK PANEL (ASSY): Sedan
REPLACEMENT
F24844A
REMOVAL
F24844-1
BODY PANEL REPLACEMENT
BP-105
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F24844-2
POINT
1
Inspect the fitting of the back door and rear combination light and other related parts before welding as this
affects the appearance of the finish.
BP-106
BODY PANEL REPLACEMENT
BACK DOOR OPENING TROUGH (ASSY):
Hatchback
REPLACEMENT
With the quarter panel and body lower back panel removed.
F22865A
REMOVAL
F22865
POINT
1
Remove [A] at the same time.
PART NAME
[A] Back Door Opening Lower Reinforcement
BODY PANEL REPLACEMENT
BP-107
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top coat, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
F22866
POINT
1
Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects
the appearance of the finish.
PART NAME
[A] Back Door Opening Lower Reinforcement
[B]
Rear Bumper Side Retainer
BP-108
BODY PANEL REPLACEMENT
LUGGAGE DOOR OPENING FRONT
TROUGH (ASSY): Sedan
REPLACEMENT
F24845A
REMOVAL
F24845-1
BODY PANEL REPLACEMENT
BP-109
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply polyurethane foam to the corresponding parts.
After welding, apply body sealer and undercoating to the corresponding parts.
After applying the top, apply anti-rust agent to the internal panel portion of the closed section structural weld
points.
(13 mm)
F24845-2
POINT
1
Inspect the fitting of the back door, rear combination light and other related parts before welding as this affects
the appearance of the finish.
13 mm (0.51 in.)